Large-format battery managment system

ABSTRACT

A battery system with a large-format Li-ion battery powers attached equipment by discharging battery cells distributed among a plurality of battery packs. The discharging of the battery cells is controlled in an efficient manner while preserving the expected life of the Li-ion battery cells. Each battery pack internally supports a battery management system and may have identical components, thus supporting an architecture that easily scales to higher power/energy. Battery packs may be added or removed without intervention with a user, where one of battery packs serves as a master battery pack and the remaining battery packs serve as slave battery packs. When the master battery pack is removed, one of the slave battery packs becomes the master battery pack. Charging and discharging of the battery cells is coordinated by the master battery pack with the slave battery packs over a communication channel such as a controller area network (CAN) bus.

CROSS-REFERENCE TO RELATED PARAGRAPHS

This application is a continuation of U.S. patent application Ser. No.16/937,931, filed Jul. 24, 2020, which is a continuation ofInternational Patent Application serial no. PCT/CN2020/093886 with aninternational filing date of Jun. 2, 2020; and this application is alsoa continuation of U.S. patent application Ser. No. 16/937,979, filedJul. 24, 2020, which is a continuation of International PatentApplication serial no. PCT/CN2020/093886 with an international filingdate of Jun. 2, 2020; and this application is also a continuation ofU.S. patent application Ser. No. 16/938,008, filed Jul. 24, 2020, whichis a continuation of International Patent Application serial no.PCT/CN2020/093886 with an international filing date of Jun. 2, 2020; andthis application is also a continuation entitled to and claiming thebenefit of priority to International Patent Application serial no.PCT/CN2020/093886, with an international filing date of Jun. 2, 2020;and all of the aforementioned are herein incorporated by reference intheir entireties.

TECHNICAL FILED

A battery system comprises a plurality of battery packs. Each batterypack includes a battery management system in which one of the batterypacks is flexibly configured as a master (e.g., primary) battery packwhile the other battery packs are configured as slave (e.g., secondary)battery packs.

The battery management systems and methods described herein may beimplemented in industrial and commercial vehicle applications, such asoff-road utility vehicles, hybrid electric vehicles, battery-electricpowered vehicles, burden carrier/tow tractors, forklift/pallet jacks,lawn and garden/outdoor power equipment, large mining equipment,automated guided vehicles, aerial work platforms, and other suchapplications. In addition, the systems and methods described herein maybe implemented in other applications including, but not limited tocordless power tools (e.g., drills, saws, grinders, nail drivers,welders, and the like), aerospace/defense applications, appliances, andother such applications. Furthermore, the systems and methods describedherein may be implemented in other applications including, but notlimited to grid energy storage, solar-generated power storage systems,sustainably generated power storage systems, smart grid systems, telecomand data communication backup systems, uniform power supply (UPS)systems, server applications, and other such applications.

For example, in some industrial and commercial vehicle applications, abattery management system such as disclosed herein may desired to outputa wide range of current—e.g., a high current when initially turning onan engine of the vehicle, however, less current during normal operationof the vehicle. The battery management system and methods may also, insome embodiments, include a limp home mode feature, as disclosed herein,to accommodate a failed battery in a large-format battery pack, such asin an industrial or commercial vehicle application. The batterymanagement systems, including various battery pack configurations andone or more buses (e.g., a CAN bus), may integrated into the industrialand commercial vehicle application.

In another example, in some telecom and/or data communication backupsystems and/or computer server applications, a battery management systemsuch as disclosed herein may provide an alternative to lead acid batteryinstallations that previously dominated these applications because oftheir low cost, straightforward scalability, accessible recyclinginfrastructure, and accessible manufacturers. In some embodiments, thebattery management systems and methods disclosed herein provide highenergy density, high rate of discharge capabilities, and lowself-discharge characteristics that make for desirable integration intotelecom and/or data communication backup systems, uniform power supply(UPS) systems, and/or computer server applications. For example, theaforementioned applications desire longer operational time frames thatare made possible by the battery management system such as disclosedherein, which extend the usable life of batteries in the battery pack byimplementing smart algorithms for charge, discharge, and balancing—e.g.,smart converter balancing, start direct balancing, start staggeredbalancing, and others. In addition, the battery management systems andmethods disclosed herein may be used in cooperation with, in someexamples, technologies such as fuel cells, ultracapacitors, flywheels,and other electrochemical batteries for use in telecom/datacommunications backup applications.

In yet another example, in some grid energy storage systems,solar-generated power storage systems, sustainably generated powerstorage systems, smart grid systems, and/or uniform power supply (UPS)systems, a battery management system such as disclosed herein mayoptimize electricity grids and enable sustainable energy sources, suchas wind and solar power, to be more economical. In one example, thesystem may be used to store solar energy received from photovoltaicpanels and a bi-directional three-phase inverter system may be managed,in some embodiments, using the battery management system disclosedherein. The renewable energy storage system may include a plurality ofbatteries in a battery pack integrated into a rack mount chassis andenclosure. Solar integrators may use the disclosed battery managementsystems and methods with large-format battery chemistries to fill theneeds of growing renewable energy storage requirements. While lead-acid,ultracapacitors, sodium sulfur, vanadium redox, flywheels, compressedair, fuel cells and pumped hydro have been used in solar energy storageapplications, with the disclosed battery management systems and methods,solar integrators may conveniently use Lithium ion for large-formatapplications. In addition, solar integrators may desire ancillaryservices for the power markets that uses micro-pulses of energy tomaintain the proper frequency of the current on the grid—e.g., frequencyregulation, and advanced smart grid functionality such as micro gridoperation, demand response, time shifting, and power dispatch. Lithiumchemistry over previous battery technologies include weight reduction,volume/footprint reduction, longer cycle-life, ability to use a greaterpercent of capacity of lithium battery without shortening rated cyclelife, faster charge times, and lower effective capacity loss at highrates of discharge. In some examples, an inverter and gatewayinteroperability may be coupled to the disclosed battery managementsystems to manage, distribute, and store energy within a smart grid. Insome examples, the smart grid system may be housed in a mobile shippingcontainer that is expandable.

In addition to grid energy storage systems, the battery managementsystems and methods disclosed herein may be integrated with off-gridpower products suitable in consumer, recreational, automotive, maritimeand/or industrial applications. In the automotive sector, auxiliarypower units (APU) may be used for transportation, construction, and/ormaintaining vital infrastructure. Battery APUs provides commercialvehicles with a rugged and dependable off-grid power source. Otheroff-grid power applications include maritime power, remote locationpower, traffic regulation, security surveillance and emergency powergenerators. Moreover, Battery APUs may be used for short and long-haultrucks, construction equipment, off-road transport (e.g., loggingtrucks), and buses. For example, commercial trucks may rely on BatteryAPUs for overnight comfort (e.g., air conditioning/heat/accessory)loads. For several off-grid applications, reliability is a major concernas failure and/or downtime is exceedingly costly.

BACKGROUND

Battery technology has evolved from the nascent era of automation whenvehicle batteries were typically large and heavy affairs using lead-acidtechnology. Battery technology has evolved to provide more electricalenergy with less space. For example, Lithium-ion (Li-ion) batteries arequickly replacing regular zinc carbon and lead batteries because theyare smaller and lighter than traditional batteries and can hold chargefor up to three times longer than big, heavy traditional batteries.Consequently, Li-ion batteries are finding applications for poweringtools, appliances, and vehicles including forklifts, cars, trucks, andso forth. Moreover, battery technology is not stagnant. For example, newsolid-state batteries use a glass electrolyte and lithium or sodiummetal electrodes, providing approximately three times as much energydensity as Li-ion batteries. In general, however, new technologybatteries may be damaged or degraded if the sensitive chemistry of thebattery is disrupted. For example, Li-ion batteries are known tomalfunction/degrade if overcharged or charged/overcharged/discharged ininappropriate ways.

A battery management system (BMS) is sometimes included with newtechnology batteries (for example, nickel metal hydride or Li-ion) toprovide battery protection, provide improved efficiency, and provide abetter user experience than previous battery technologies. The batterymanagement system may sometimes be implemented to further one or moregoals. For example, the EMS may be used to protect a user of theapplication being powered by the battery. As a further example, the BMSmay be used to protect the battery pack itself from damage and abusebecause the battery may often an expensive investment. Furthermore,since the battery may be an expensive investment, the EMS may be used tomaximize the performance that can be squeezed out of the battery system.Even further, the BMS may be used to maximize the life of theconstituent battery cells.

SUMMARY

A battery system may comprise a plurality of battery packs that may havethe same or similar electrical and electronic components and/orchemistries. Each battery pack may support battery cells (often Li-ion).Battery packs need not require a specific configuration before thebattery pack is installed in the battery system. Rather, the batterypack may assume a role of either a master (e.g., a primary) battery packor a slave (e.g., a secondary) battery pack after the battery pack isinserted into the system and commences activity on the communicationchannel without user intervention.

With another aspect, the battery system need not utilize an externalbattery management system. Rather, each battery pack may include aninternal battery management system that can manage a pack's batterycells and may coordinate via messaging with the other battery packs inthe battery system via a communication channel.

With another aspect, a master battery pack may gather battery statusinformation from one or more slave battery packs by messaging over acommunication channel. Based on this status information, the masterbattery pack can appropriately initiate the enabling/disabling of thecharging or discharging of battery cells located at the slave batterypacks.

With another aspect, a configuration list may be sent by a masterbattery pack to slave battery packs over a communication channel (forexample, serial communication channel such as a controller area network(CAN) bus), where the configuration list may include entries for each ofthe master and slave battery packs. The entry at the top position canserve as the master battery pack while the other battery packs can serveas slave battery packs. When a battery pack is added or removed, theconfiguration list can be revised to reflect the change.

With another aspect, battery packs in a battery system may becharge-balanced to mitigate and/or prevent in-rush electrical currentthat may occur for one or more of a plurality of battery packs in thebattery system when there is significant variation of state of charge(SoC) among the battery packs. For example, a large SoC variation mayoccur when a new battery pack is installed in a battery system, such aswhen a SoC of the new battery pack is much different (e.g., discharged,fully charged) when compared to the existing battery packs in thebattery system. In-rush electrical current can be particularlyundesirable with Li-ion batteries since its life may be substantiallyreduced.

With another aspect, different balancing technique of battery packs aresupported in a battery system. Based on the SoC characteristics of thebattery packs, one of a plurality of balancing techniques may beselected. Balancing techniques may include, for example, a “smartconverter balancing,” a “start direct balancing,” and/or a “startstaggered balancing.”

With another aspect, a battery system may support a “limp home mode”when a battery pack in a battery system experiences a catastrophicfailure, for example, when its battery cells are characterized by a verylow voltage output. An internal battery management system may diagnosethe failure and may mitigate the failure by configuring an unusedbattery pack (if available) in the battery system or by initiating apartial shutdown of the battery system, enabling operation of theequipment to “limp home” under at least partial power.

With another aspect, a battery system supports “smart discharge” inorder to power equipment (end device). Battery packs with varying SoC'smay be connected to an end device to provide electrical power to thedevice. However, battery packs that have a large SoC variation cannot beimmediately connected together to power the end device and maynecessitate charge balancing to be performed. Battery packs are thenselectively enabled from a plurality of battery packs in the batterysystem so that the battery packs can properly discharge.

With another aspect, a battery system supports “smart charge” in orderto restore charge to its battery cells. A battery system having batterypacks with varying SoC's may be connected to a charger in order torestore the SoC's of each battery pack and to reduce the SoC variabilityamong the battery packs. If the battery packs have a large SoCvariation, the battery packs cannot be immediately connected to thecharger at the same time. Measures are thus supported to circumvent thissituation by enabling charging of selected battery packs at theappropriate time based on dynamic SoC characteristics.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing summary, as well as the following detailed description ofexemplary embodiments, is better understood when read in conjunctionwith the accompanying drawings, which are included by way of example,and not by way of limitation with regard to the claimed invention.

FIG. 1 shows an end device electrically powered by a plurality ofbattery packs in accordance with an embodiment.

FIG. 2A shows a battery pack with an internal battery management system(BMS) in accordance with an embodiment.

FIG. 2B shows a battery pack with an internal battery management system(BMS) in accordance with an embodiment.

FIG. 3 shows a flowchart for an overall process of electrically poweringan end device by a plurality of battery packs in accordance with anembodiment.

FIG. 4 shows an updating of a configuration list of a plurality ofbattery packs in accordance with an embodiment.

FIG. 5 shows a flowchart for configuring a plurality of battery packs inaccordance with an embodiment.

FIG. 6A shows a generic message flow scenario for configuring aplurality of battery packs in accordance with an embodiment.

FIG. 6B shows a message flow scenario over a controller area network(CAN) bus for configuring a plurality of battery packs in accordancewith an embodiment.

FIG. 6C shows another message flow scenario over a controller areanetwork (CAN) bus for configuring a plurality of battery packs inaccordance with an embodiment.

FIG. 6D shows another message flow scenario over a controller areanetwork (CAN) bus for configuring a plurality of battery packs inaccordance with an embodiment.

FIG. 7A shows a flowchart for determining a balancing type for aplurality of battery packs in accordance with an embodiment.

FIG. 7B shows a flowchart for selecting one of three balancing types fora plurality of battery packs in accordance with an embodiment.

FIG. 7C shows a flowchart for determining a balancing type for aplurality of battery packs in accordance with an embodiment.

FIG. 8 shows a message flow scenario for determining a balancing typefor plurality of battery packs in accordance with an embodiment.

FIG. 9 shows a flowchart for converter balancing with a plurality ofbattery packs in accordance with an embodiment.

FIG. 10 shows a message flow scenario for converter balancing with aplurality of battery packs in accordance with an embodiment.

FIG. 11 shows a flowchart for direct balancing with a plurality ofbattery packs in accordance with an embodiment.

FIG. 12 shows a message flow scenario for direct balancing with aplurality of battery packs in accordance with an embodiment.

FIG. 13 shows a flowchart for staggered balancing with a plurality ofbattery packs in accordance with an embodiment.

FIGS. 14-15 show a message flow scenario for staggered balancing with aplurality of battery packs in accordance with an embodiment.

FIG. 16 shows an example of charging a plurality of battery packs inaccordance with an embodiment.

FIG. 17 shows a flowchart for charging a plurality of battery packs inaccordance with an embodiment.

FIG. 18A shows a message flow scenario for charging a plurality ofbattery packs in accordance with an embodiment.

FIG. 18B shows a message flow scenario for charging a plurality ofbattery packs in accordance with an embodiment.

FIG. 18C shows a flowchart of a method for intelligently charging aplurality of battery packs in accordance with an embodiment.

FIG. 19A shows an example of a plurality of battery packs discharging inorder to electrically power an end device in accordance with anembodiment.

FIG. 19B shows an example of a plurality of battery packs discharging inorder to electrically power an end device in accordance with anembodiment.

FIG. 20A shows a flowchart for discharging a plurality of battery packsin accordance with an embodiment.

FIG. 20B shows a flowchart for discharging a plurality of battery packsin accordance with an embodiment.

FIG. 21 shows a message flow scenario for discharging a plurality ofbattery packs in accordance with an embodiment.

FIG. 22 a flowchart for limp home mode operation in accordance with anembodiment.

FIG. 23A shows a message flow scenario for limp home mode operation inaccordance with an embodiment.

FIG. 23B shows a message flow scenario for limp home mode operation inaccordance with an embodiment.

DETAILED DESCRIPTION

According to an aspect of the embodiments, a battery system with alarge-format battery (e.g., a Li-ion battery) powers attached equipment(an end device) by discharging battery cells distributed among aplurality of battery packs. The discharging of the battery cells iscontrolled in an efficient manner while preserving the expected life ofthe Li-ion battery cells.

According to another aspect of the embodiments, a battery system maysupport different advanced technology batteries of different chemistriesand/or structures including, but not limited to, Li-ion batteries andsolid state batteries.

Each battery pack internally supports a battery management system (BMS),thus circumventing the need of an external battery management incontrast to traditional approaches. Moreover, each of the battery packsmay have identical electrical and electronics components, thussupporting an architecture that easily scales to higher power/energyoutput as needed by an end device. Battery packs may be individuallyadded or removed, where one of the battery packs serves as a masterbattery pack and the remaining battery packs serve as slave batterypacks. Moreover, configuration of the battery packs may be automaticallyperformed without user interaction. When the master battery pack isremoved, one of the slave battery packs is automatically reconfigured tobecome the master battery pack. Charging and discharging of the batterycells is coordinated by the master (e.g., primary) battery pack with theslave (e.g., secondary) battery packs over a communication channel suchas a controller area controller (CAN) bus.

In addition, the battery system may be efficiently charged in order torestore charge to the battery cells while preserving the life expectancyof the battery cells.

Rechargeable medium-to-large format battery packs with batterymanagement systems are providing power for small, portable devices andare also extending to larger mobile and stationary uses. Moreover,transportation applications spanning smaller uses such as scooters tolarger ones such as full-size autos are contemplated with rechargeablebatteries. Industrial applications are also contemplated asbattery-based designs are replacing small internal combustion enginesfor lawn mowers and yard equipment in both commercial and consumerproducts. Enabling electrification has several advantages, including butnot limited to, elimination of polluting emissions, reduced noise, andlower maintenance needs. Furthermore, self-contained backup powersystems for residential and commercial sites are benefiting frombattery-based designs which eliminate the issues associated with on-sitehydrocarbon-based fuel storage.

FIG. 1 shows end device 101 electrically powered by a plurality ofbattery packs 100 (battery system) in accordance with an embodiment.Each battery pack 102, 103, and 104 includes its own internal batterymanagement system (BMS) 112, 113, and 114, respectively. Battery packs102, 103, and 104 are electrically connected to a direct current (DC)power bus 151 (comprising positive and negative connections) so that thevoltage presented to end device 101 is essentially the same as thevoltage provided by each battery pack 102, 103, and 104 while theelectrical current supplied to end device 101 is the sum of individualelectrical currents provided by each battery pack. Battery packs 100 maybe housed within end device 101, mounted to end device 101, orexternally situated with respect to end device 101.

End device 101 may assume different types of devices including, but notlimited to, power tools, lawn mowers, garden tools, appliances, andvehicles including forklifts, cars, trucks, and so forth.

Battery management systems 112, 113, and 114 communicate with all of thebattery packs as well as end device 101 and/or charger 1601 (as shown inFIG. 16) over communication channel 152. For example, communicationchannel 152 may comprise a serial communication channel (e.g., acontroller area network (CAN) bus) or a parallel communication bus.However, embodiments may support other types of communication channelssuch as Ethernet, Industrial Ethernet, I²C, Microwire, or Bluetooth LowEnergy (BLE). In some cases, the communication channel may supportsynchronous communication (e.g., CAN) or asynchronous communication(e.g., RS-232, RS-422, RS-485, etc.)

The CAN and Ethernet protocols support the lower two layers of the OSImodel while the BLE protocol spans the lower layers as well as thehigher layers including the application layer. Consequently, embodimentsutilizing protocols such as CAN and Ethernet must support the equivalenthigher layers by software applications built on top of the two lowerlayers.

Embodiments may support different messaging protocols. For example, aprotocol may support node to node communication by supporting both asource address and a destination address. The destination address mayspecify a particular node address or may be a global address so that amessage may be broadcast to more than one node. In some cases, aprotocol (such as the CAN protocol, the Modbus protocol, etc.) maysupport only a single source address (e.g., a master address) so thatall nodes may process a message broadcast over a communication channel.

Battery packs 102, 103, and 104 may each connect to communicationchannel 152 in a parallel fashion. However, embodiments may supportdifferent arrangements such as pack-to-pack communication on separatebusses or a daisy chain connection through each battery pack.

Battery packs 102, 103, and 104 may have similar or identical electricaland electronic components. After being inserted into a battery system,one of the battery packs 102, 103, or 104 may be configured as a masterbattery pack or a slave battery pack. Moreover, if a battery packinitially serves as a slave battery pack, it may subsequently serve as anew master battery pack if the current master battery pack is removed.

FIG. 2A shows battery pack 200 with an internal battery managementsystem (BMS) in accordance with an embodiment. The battery managementsystem may be implemented by processor 201, which may comprise one ormore microprocessors, controllers, microcontrollers, computing devices,and/or the like, executing computer-executable instructions stored atmemory device 202.

As will be discussed, battery pack 200 may be configured as either amaster battery pack or a slave battery pack without any change to theelectrical or electronic components.

The power circuitry (including battery cells 203) of battery pack 200interacts with power bus 151 through power bus interface circuit 206when battery pack 200 is discharging, charging, and/or being balancedwith respect to the other battery packs as will be discussed.

Battery pack 200 also interacts with communication channel 152 viacommunication channel interface circuit 205. For example, battery pack200 may support messaging with other configured battery packs, with theend device being powered by the battery packs, or with a chargercharging battery cells 203. Exemplary message flows are shown in FIGS.6A-B, 8, 10, 12, 14-15, 18A-B, 21, and 23A-B as will be discussed infurther detail.

Battery pack 200 supports core battery monitoring and/or managementfunctionality via core battery functions circuit 204. For example, corebattery functions may include battery cell status, battery cellbalancing, short circuit protection, high temperature cut-off,over-current cut-off, and over-charge protection.

Referring to FIG. 2A, battery cells 203 may include a plurality ofbattery cells that are connected in series to obtain a desired voltagelevel. For example, with Li-ion technology, each battery cell may have anominal voltage of approximately 3.6 volts. With four battery cellsconnected in series, the total nominal voltage provided by battery pack200 is approximately 14.4 volts. When battery cells 203 comprises aplurality of battery cells, core battery functions circuit 204 mayinternally balance the charge among the different battery cells. Inaddition, battery pack 200 may be charge balanced with respect to theother battery packs in a battery system. The battery packs are oftenconfigured in a parallel fashion so that the resultant electricalcurrent offered to an end device is the sum of electrical currents ofthe battery packs at an approximate voltage level of an individualbattery pack.

Status information may include the state of charge (SoC) information,state of health (SoH) information, temperature information, chargingtime information, discharge time information, and/or capacityinformation of the battery cells and/or of the battery pack.

As one with skill in the art would appreciate, the SoC is understood tobe the level of charge of an electric battery relative to its capacity.The units of SoC are typically percentage points (0%=empty; 100%=full).

The SoH typically does not correspond to a particular physical qualitysince generally there is no consensus in the industry on how SoH shouldbe determined. However, the SoH is indicative of internal resistance,battery storage capacity, battery output voltage, number ofcharge-discharge cycles, temperature of the battery cells duringprevious uses, total energy charged or discharged, and/or age of thebattery cells to derive a value of the SoH. Knowing the SoH of thebattery cells of battery pack 200 and the SoH threshold of a given enddevice (application) may provide a determination whether the presentbattery conditions are suitable for an application and an estimate aboutthe battery pack's useful lifetime for that application.

When performing processes associated with battery management, batterypack 200 may receive or send values of at least the SoC and/or SoHfrom/to other battery packs as will discussed in further detail.

Power bus interface circuit 206 may comprise a switch circuit such as asemiconductor array 210 (for example, a MOSFET array or other powersemiconductor switch device, such as an insulated gate bipolartransistor (IGBT) array, a thyristor array, etc.) that allows electricalcurrent flow from battery pack 200 when battery pack 200 is dischargingand semiconductor array 211 that allows electrical current flow tobattery pack 200 when battery pack 200 is charging. Arrays 210, 211 areappropriately enabled by processor 201 in response to messaging from themaster battery pack controller. (In a situation when battery pack is themaster battery pack, messaging is internal to battery pack 200 rathervia communication channel 152.) The power MOSFET arrays (e.g., N-ChannelMOSFETs) may be used as switches to control power flow to and from thebattery cells. The gates of the MOSFET arrays may be controlled bysignals generated by a microcontroller and/or a battery management IC.

Power bus interface circuit 206 may be configured to prevent batterypack 200 from being charged or discharged through power bus 206 based onthe status of battery cells 203 (for example, SoC, SoH, and/or voltage).Typically, arrays 210 and 211 are disabled when a battery pack isinserted into a battery system so that the battery pack does not chargeor discharge until instructed and/or controlled by the master batterypack.

Battery pack 200 interacts with power bus 151 via electrical switch 208(which may comprise one or more semiconductor devices). As shown in FIG.2, direct exposure to power bus 151 bypasses converter 207. However, ifbattery cells are charged when the battery cells have a small SoC, thebattery cells may incur an electrical current in-rush, often resultingin damage or degradation. Consequently, when the battery managementsystem detects such a condition, electrical switch 208 may be configuredso that charging of the battery pack 200 is controlled to minimizeinrush current from the power bus 151 via the converter 207.

Converter 207 may assume different forms capable of controlling powertransfer between the power bus and the cells of the battery pack such asby providing a stepped-down output voltage with respect to the inputvoltage (e.g., a buck converter, a auk converter, a buck-boostconverter, a single-ended primary-inductor converter (SEPIC) converter,etc.) to protect battery cells 203 from an electrical current in-rushand enable battery cells 203 to slowly charge (for example,corresponding to converter balancing flowchart 713 as shown in FIG. 9).However, when converter 207 is bypassed, battery cells 203 may charge ata quicker rate (for example, corresponding to direct balancing flowchart714 as shown in FIG. 11).

Processor 201 may support battery management processes (for example,processes 500, 700, 713, 714, 715, 1700, 2000, and 2200 as shown inFIGS. 5, 7A, 9, 11, 13, 17, 20, and 22, respectively) discussed herein.Processor 201 may control the overall operation of battery pack 200 andits associated components. Processor 201 may access and execute computerreadable instructions from memory device 202, which may assume a varietyof computer readable media. For example, computer readable media may beany available media that may be accessed by processor 201 and mayinclude both volatile and nonvolatile media and removable andnon-removable media. By way of example, and not limitation, computerreadable media may comprise a combination of computer storage media andcommunication media.

Computer storage media may include volatile and nonvolatile andremovable and non-removable media implemented in any method ortechnology for storage of information such as computer readableinstructions, data structures, program modules or other data. Computerstorage media include, but is not limited to, random access memory(RAM), read only memory (ROM), electronically erasable programmable readonly memory (EEPROM), flash memory or other memory technology, CD-ROM,digital versatile disks (DVD) or other optical disk storage, magneticcassettes, magnetic tape, magnetic disk storage or other magneticstorage devices, or any other medium that can be used to store thedesired information and that can be accessed by the computing device.

Communication media may include computer readable instructions, datastructures, program modules or other data in a modulated data signalsuch as a carrier wave or other transport mechanism and includes anyinformation delivery media. Modulated data signal can be a signal thathas one or more of its characteristics set or changed in such a manneras to encode information in the signal. By way of example, and notlimitation, communication media may include wired media, such as a wirednetwork or direct-wired connection, and wireless media such as acoustic,RF, infrared and other wireless media.

While processor 201 and communication channel interface circuit 205 maybe powered by battery cells 203, embodiments may have a separate powersource for processor 201 and interface circuit 205. Consequently,battery pack 200 may continue to interact with the other battery packsover the communication channel regardless of the status of battery cells203.

FIG. 2B shows a variation of battery pack 200 shown in FIG. 2A. Batterycells 210 interact with the power bus through power bus connector 214,switch 217, converter 218, and connector 219. Switch 217 may include twosets (arrays) of semiconductor devices (for example, MOSFET's,insulated-gate bipolar transistors (IGBTs), thyristors, and so forth)for allowing electrical current flow in either direction (into thebattery pack for charging and out of the battery pack for discharging).Both arrays may be disabled to isolate the battery pack from the powerbus. Typically, both arrays are disabled when a battery pack is insertedinto a battery system. In addition, enabled converter 218 may be used toreduce an input voltage level to control charging of the battery cellsto prevent an electrical current in-rush that may occur in somesituations as will be discussed.

Controller 213 executes computer-executable instructions to performprocesses discussed herein. For example, controller 213 obtains statusinformation (for example, the SoC value) from battery cells 210 viabattery monitor 211, provides battery pack status information via statusdisplay 215, and interacts with a communication channel (for example, aCAN bus) via communication bus interface 216.

In addition, a heater control circuit 212 may be used to ensure that thetemperature of battery cells 210 does not drop below a minimum value sothat battery cells 210 can properly operate as expected.

FIG. 3 shows flowchart 300 for an overall process of electricallypowering an end device (for example, end device 101 as shown in FIG. 1)by a plurality of battery packs (for example, battery packs 100) inaccordance with an embodiment.

At block 301, end device 101 is activated. For example, a user may closea battery compartment of end device 101, turn a key, and/or flip aswitch to generate an interlock signal.

At block 302, the battery management system of the master battery packdetermines whether to balance the battery packs when the batterycompartment has more than two battery packs. If so, the difference ofcharge of the battery packs may be reduced by one or more battery packsdischarging to charge one or more of the other battery packs at block303 as will be discussed in further detail.

After balancing (if needed), the end device is powered by dischargingone or more of the battery packs at block 304. For example, based on thepower requirements of the end device and the SoC values of the batterypacks, the battery management system of the master battery pack mayenable the appropriate battery packs.

If a catastrophic failure is detected at block 305 for one of theenabled battery packs while powering the end device, limp home modeoperation at block 306 may be initiated in order to continue poweringthe end device as will be discussed in further detail.

When the user completes using the end device at block 307, block 308determines whether charging is needed. If so, a charger may be connectedto the battery system to restore the battery cells, where charging maybe initiated at block 309.

While not explicitly shown, balancing of the battery packs may beperformed before charging the battery packs at block 308 when the SoCvalues of the battery packs are sufficiently different.

With the embodiments, all of the plurality of battery packs may have thesame electrical and electronic components. No configuration is typicallyneeded to a battery pack when the battery pack is installed in thebattery system. Rather, the battery pack assumes the role of either amaster battery pack or a slave battery pack based on processes discussedherein after the battery pack is inserted into the system and thebattery pack commences activity on the communication channel. As will bediscussed in further detail, a configuration list may be conveyed overthe communication channel, where the configuration includes entries foreach of the master and slave battery packs.

The processes discussed herein are shown from the perspective of themaster battery pack and are typically executed by the master batterypack in the battery system. The other installed battery packs in thebattery system serve as slave battery packs. However, the slave batterypacks interact with the master battery pack over the communicationchannel. For example, a slave battery pack provides its battery cellstatus information and activates/deactivates power switches to interactwith the power bus (for example, allowing electrical current (charge) toflow into or from the battery pack) responsive to messaging from themaster battery pack. Consequently, while not explicitly shown, there arecorresponding processes executed by each of the slave battery packs.

FIG. 4 shows an updating of configuration list 401 a,401 b,401 c,401 dof a plurality of battery packs as different battery packs are insertedinto and removed from the battery system. Each battery pack is assignedan identification (ID) in accordance with a standardized process, suchas the SAE J1939 Address Claim Procedure and/or the like. For example,configuration list 401 a contains four entries: pack 1 (which isconfigured as the master battery pack) and three slave battery packs(packs 2-4).

As will be discussed in greater detail, the master battery pack gatherstatus information about the other battery packs (the slave batterypacks) and consequently instructs the slave battery packs, as well asitself, to discharge or charge in response to the operation situation.

With the embodiment shown in FIG. 4, the first (top) member ofconfiguration list 401 a,401 b,401 c,401 d is configured as the masterbattery pack. When a battery pack is added to the battery system, anentry is created at the bottom of the configuration list for thatbattery pack. Consequently, the oldest member of configuration list 401a,401 b,401 c,401 d is configured as the master battery pack.

Selecting the oldest (top) member of configuration list 401 c may beadvantageous to traditional approaches. For example, the number ofchanges of the master battery packs may be reduced with respect todetermining the master battery pack based on the ID value. With thelatter approach, a second change would occur from configuration list 401d, where pack 5 would become the master battery pack.

In the installation scenario shown in FIG. 4, pack 1 (which serves asthe master battery pack) is removed as shown in configuration list 401b. Consequently, pack 2 (the oldest slave battery pack) becomes the newmaster battery pack as shown in configuration list 401 c. In order tocomplete the transition, pack 2 may request pack information from theother battery packs to be able to properly instruct the other batterypacks.

Subsequently, pack 5 is inserted into the battery system resulting in anew entry being added to configuration list 401 d, where ID 243 is thesame ID for previously removed pack 1. With embodiment shown in FIG. 4,pack 5 may be old master pack that is reinserted or a new battery packthat is inserted into the battery system.

With some embodiments, when a battery pack is removed from a batterysystem, battery pack information may be lost. When the battery pack isreinserted, the reinserted battery pack may obtain battery informationfrom the configured battery packs. However, some embodiments may supportmemory persistence (e.g., flash memory) so that battery pack informationis retained at the battery pack even when the battery pack is removedand reinserted.

FIG. 5 shows flowchart 500 for configuring a plurality of battery packsin accordance with an embodiment. At block 501, a battery pack is addedto the battery system. If no other battery packs are connected to thecommunication channel, as determined at block 502, an entry is added tothe top of the configuration list, and the battery pack becomes themaster battery pack at block 504. Otherwise, the added battery pack isadded to the bottom of the configuration list and becomes a slavebattery pack at block 503.

At block 504, a battery pack is removed from the battery system. If thebattery pack is the first member of the configuration list, asdetermined at block 505, the entry is removed at block 506 and thebattery pack corresponding to the next entry is designated as the masterbattery pack at block 507. Otherwise, the entry for the removed batterypack is deleted at block 508.

FIG. 6A shows a generic message flow scenario for configuring aplurality of battery packs in accordance with flowchart as shown in FIG.5. The generic messages represent messages supported by differentcommunication channels, for example via a controller area network (CAN)bus, Ethernet, Industrial Ethernet, MODBUS, or Bluetooth Low Energy(BLE) and/or the like.

The message flow in FIG. 6A is based on a centralized approach, in whichthe master battery pack maintains the configuration list andrepetitively sends it (for example, periodically) to the other batterypacks over a communication channel. However, embodiments (for example,as shown in FIG. 6D) may support a distributed approach, in which eachbattery pack locally maintains its own configuration list andrepetitively broadcasts it over the communication channel. Since abattery pack receives all broadcasts from the other battery packs, thebattery pack is able to modify its own configuration list to beconsistent with the configuration lists broadcast by the other batterypacks.

When pack 601 (pack 1) becomes the master battery pack at event 631,pack 601 sends periodic update messages 661 a,661 b,661 c to packs 602,603, and 604, respectively. If the message protocol supports a singlebroadcast message (for example, with a global destination address) thatis received and processed by all battery packs connected to thecommunication channel, then only one message is sent by pack 601.Otherwise, pack 601 sends separate messages to packs 602, 603, and 604(which are configured as slave battery packs).

With some embodiments, messages 661 a, 661 b, 661 c may be sentrepetitively but not periodically.

Periodic update message 661 a, 661 b, 661 c may contain configurationinformation (for example configuration list 401 a, 401 b, 401 c, 401 das shown in FIG. 4). With some embodiments, pack 601 sends broadcastmessages periodically. However, if pack 601 were removed (for example,corresponding to event 632), periodic transmission of the updatemessages would be disrupted.

When the disruption is detected by the oldest slave battery pack (pack602) at event 633, pack 602 assumes the role of the master battery pack.Consequently, pack 602 removes the top entry of the configuration list(corresponding to pack 601) and periodically sends the revisedconfiguration list via update message 662 a,662 b.

When pack 605 (pack 5) is added at event 634, pack 605 sends joinrequest 663 in accordance with the SAE J1939 address claim procedure.Consequently, pack 605 is added by pack 602 (currently the masterbattery pack) at event 635, and pack 602 periodically sends updatemessages 664 a, 664 b, 664 c and 665 a, 665 b, 665 c.

FIG. 6B shows a message flow scenario over a CAN bus for configuring aplurality of battery packs in accordance with an embodiment.

The CAN communications protocol (ISO-11898: 2003) describes howinformation is passed between devices on a network and conforms to theOpen Systems Interconnection (OSI) model that is defined in terms oflayers. Actual communication between devices connected by the physicalmedium is defined by the physical layer of the model. The ISO 11898architecture defines the lowest two layers of the seven-layer OSI/ISOmodel referred as the data-link layer and physical layer.

The CAN communication protocol supports both a standard version (11-bitidentifier field) and an extended version (29-bit identifier field).However, embodiments typically use the standard version because thesupported identifier space is typically more than enough.

The CAN bus is often referred to as a broadcast type of bus, where eachmessage contains a source address (for example, a device ID) but not adestination address. Consequently, ail battery packs (corresponding tonodes) can “hear” all transmissions. A battery pack may selectivelyignore a message or may process the message by providing local filteringso that each battery pack may respond to pertinent messages.

Embodiments may use the data frame message specified in the CANprotocol. This message type carries a 0-8 byte payload, where the datafield is interpreted at a higher protocol layer (typically by a softwareapplication executing at the battery packs). For example, the data fieldmay convey SoC and/or SoH information when a slave battery pack sendsstatus information back to the master battery pack.

In order to assign an identification value (address) to a battery pack,end device, or charger, embodiments may utilize an industry standard,such as the SAE J1939 address claim procedure. The SAE J1939 protocol isa higher protocol layer built on top the CAN data-link and physicallayers.

Referring to FIG. 6B, when pack 601 (pack 1) becomes the master batterypack at event 636, pack 601 sends periodic data frame message 671 topacks 602, 603, and 604, respectively. (Because the CAN protocolsupports only a source address, all battery packs may receive andprocess a single broadcast message sent via the CAN bus.) Data framemessage 671 corresponds to periodic update message 661 a, 661 b, 661 cshown in FIG. 6A. Data frame message 671 contains at least theconfiguration list in the payload.

When pack 601 is removed (for example, corresponding to event 637),periodic transmission of the periodic data frame messages is disrupted.

When the disruption is detected by the oldest slave battery pack (pack602) at event 638, pack 602 assumes the role of the master battery pack.Consequently, pack 602 removes the top entry of the configuration list(corresponding to pack 601) and periodically sends the revisedconfiguration list via data frame message 672.

When pack 605 (pack 5) is added at event 639, pack 605 initiates theaddress claimed procedure 673 claiming its identification (ID) value.When successfully completed, an entry with the identification of pack605 is added to the bottom of the configuration list by master batterypack 602 at event 640.

Subsequently, pack 602 (now the master battery pack) periodically sendsbroadcast data frame message 674.

FIG. 6C shows a variation of the message flow scenario shown in FIG. 6Bfor configuring a plurality of battery packs in accordance with anembodiment. As with FIG. 6B, pack 601 (designated as the master batterypack at event 641) periodically sends the configuration list via message681. However, slave battery packs 602, 603, and 604 return confirmationmessages 682 a-c to confirm reception.

At event 642, battery pack 604 is removed from the battery system. Whenbattery pack 601 periodically sends message 683, only messages 684 a-bare returned. Consequently, a message timeout occurs at event 643, andmaster battery pack 601 detects that battery pack 604 has been removedand removes the entry for battery pack 604 from the configuration list.The modified configuration list is included in the next periodicbroadcast.

FIG. 6D shows a variation of the message flow scenario shown in FIG. 6B,where the configuration list is maintained in a distributed rather thana centralized fashion.

Battery pack 601 is distributed as the master battery pack at event 644.Rather than the master battery pack maintaining and sending theconfiguration list to the other battery packs, each of the activebattery packs 601-604 maintains its own configuration list andbroadcasts it via messages 691 a-d to the other battery packs via theCAN bus, where list_1, list_2, list_3, and list_4 correspond to theconfiguration messages maintained at battery packs 601-604,respectively. As necessary, battery packs 601-604 may modify its ownconfiguration list to be consistent with the configuration listsbroadcast by the other battery packs. For example, a battery pack mayhave been recently inserted into a battery system and may need to reviseits configuration list to be consistent with the current configuration.

When pack 601 is removed (for example, corresponding to event 645),periodic transmission of the periodic data frame messages from batterypack 601 terminates.

When the termination is detected by battery packs 602-604 at event 646,pack 602 assumes the role of the master battery pack. Consequently,packs 602-604 remove the top entry of the configuration list(corresponding to pack 601) that is locally maintained at the batterypacks 602-604 and periodically send the revised configuration list viadata frame messages 692 a-c.

When pack 605 (pack 5) is added at event 647, pack 605 initiates theaddress claimed procedure 693 claiming its identification (ID) value.When successfully completed, battery packs 602-604 adds pack 5 to thebottom of the local copy of the configuration list. 605 at event 648,and subsequently the revised configuration list is broadcast via dataframe messages 694 a-d. With an aspect of the embodiments related tobalancing, as will be discussed, the in-rush of electrical current amongmultiple Li-ion battery packs in a large-format battery pack system isan undesirable phenomenon arising with Li-ion battery cells since alarge in-rush electrical current may reduce the life of Li-ion batterycells. This phenomenon may occur due to a large variation of SoC valuesamong the battery packs in the battery system. For example, when a brandnew Li-ion battery pack is added to a battery pack system, its capacity(e.g., energy level) at the beginning of its new life may be notablydifferent than capacities of the battery cells of older battery packsalready present in the battery pack system. This energy leveldifferential between the cells of the new battery pack and the cells ofthe older battery packs can potentially damage the other Li-ion batterycells in the battery pack system. The aspect involves a balancingtechnique that leverages the internal (not external) battery managementsystem and the master-slave topology.

As previously discussed, some embodiments order a configuration listbased on the time that battery packs are connected to the communicationchannel (for example, CAN bus). With this approach, the oldest batterypack is designated as the master battery pack. However, otherembodiments may use different approaches. For example, the members ofthe configuration list may be ordered from top to bottom by decreasingvalues of the open circuit voltages of the battery packs. The opencircuit voltage of a battery pack may be measured when the batterypack's discharging array is disabled (in other words, the battery packis not discharging onto the power bus of the battery system).

Each battery pack can share its measured open circuit voltage with theother battery packs that are connected to the communication channel.Based on the measured open circuit voltages, a configuration list ismaintained, where entries for each battery pack are listed by decreasingorder. The battery pack corresponding to the top entry has the largestopen circuit voltage and serves as the master battery pack for batterysystem. With an exemplary embodiment, a battery system comprises first,second, and third battery packs having open circuit voltages V_(open1),V_(open2), and V_(open3), respectively, whereV_(open2)>V_(open3)>V_(open1). The top entry of the configuration listis associated with the second battery pack (the master battery pack)followed by an entry for the third battery pack followed by an entry forthe first battery pack. Consequently, if the second battery were tofail, the third battery pack would assume the role of the master batterypack.

With some embodiments, the battery packs in a battery system areassigned an ID and at the same time the open circuit voltage may bemeasured and stored in the configuration list. In the infrequentsituation where the open circuit voltages of two battery packs areequal, one battery pack may be chosen randomly or may be chosen by thehighest number ID.

The configuration list may be updated as battery packs are installedinto the battery system. For example, a battery pack that is installedafter discharging begins would initially enter in a standby mode (wherethe discharging array is disabled) so that an open circuit voltage canbe measured by the battery pack. The newly installed battery pack couldthan share the measured open circuit voltage with the other batterypacks via the communication channel. With some embodiments, theconfiguration list can then be updated with an entry for the newlyinstalled battery pack based on the measured open circuit voltage.However, with some embodiments, the current configuration list mayremain unchanged until the battery packs being discharged aredisconnected from the battery system.

With some embodiments, the configuration list may be centrallymaintained by the master battery pack. However, with some embodiments,each battery pack in the battery system may maintain its own copy of theconfiguration list based on information shared via the communicationchannel.

With an aspect of the embodiments related to balancing, as will bediscussed, the in-rush of electrical current among multiple Li-ionbattery packs in a large-format battery pack system is an undesirablephenomenon arising with Li-ion battery cells since a large in-rushelectrical current may reduce the life of Li-ion battery cells. Thisphenomenon may occur due to a large variation of SoC values among thebattery packs in the battery system. For example, when a brand newLi-ion battery pack is added to a battery pack system, its capacity(e.g., energy level) at the beginning of its new life may be notablydifferent than capacities of the battery cells of older battery packsalready present in the battery pack system. This energy leveldifferential between the cells of the new battery pack and the cells ofthe older battery packs can potentially damage the other Li-ion batterycells in the battery pack system. The aspect involves a balancingtechnique that leverages the internal (not external) battery managementsystem and the master-slave topology.

With an aspect of the embodiment, different balance techniques forLi-ion battery cells may be supported in a large-format battery packsystem. For example, the aspect includes three balancing techniques:“smart converter balancing,” “start direct balancing,” and “startstaggered balancing” that may be used in a medium-large battery packimplementation to ensure the safe use and longevity of the Li-ionbattery cells. The aspect may utilize a converter (with a cellpre-charge circuit) for charge balancing each battery pack to preventand/or limit in-rush electrical current, over-current faults, and/orshort-circuit faults.

FIG. 7A shows flowchart 700 for determining a balancing type for aplurality of battery packs in accordance with an embodiment.

At block 701, the master battery pack transitions from a sleep state.For example, when an end device is not being used, the master batterypack may periodically wake up to determine whether there is a change inthe operational state.

At block 702, the master battery pack determines the number of batterypacks that are installed in the battery system. For example, the masterpack may verify that all battery packs on the confirmation list areactive on the communications channel.

At block 704, the master battery pack determines whether a minimumnumber of battery packs (including itself) are installed based on powerrequirements of a device (for example, obtained from the end device viathe communication channel).

If there are not a minimum number of battery packs available to properlypower the end device, then the configured battery packs are preventedfrom discharging at block 705 by the master battery pack instructing theslave battery packs (as well as itself) to open corresponding dischargearrays. A fault indicator is activated at block 706 that is indicativethat not enough battery packs are installed to power the end device. Ifan additional battery pack is installed at block 707, the faultindicator is cleared at block 708. If the end device is activated orotherwise enabled at block 709 (for example, the key is in the “on”position), process 700 returns to block 704. Otherwise, process 700returns to block 701.

Returning back to block 704, when the master battery pack determinesthat there are a sufficient number of battery packs, the master batterypack gathers battery pack information (for example, SoC, SoH, andvoltage information) from each of the slave battery packs as well as foritself at block 710. For example, as will be discussed in furtherdetail, the master battery pack may send a “Request for Pack Info”message to each of the configured slave battery packs and receive a“Pack Info” message from each slave battery pack in response with therequested information.

From the gathered SoC data, the master battery pack determines whetherbalancing is required at block 711. For example, some of the batterypacks may have a high SoC while some may have a low SoC. By balancingthe battery packs, a sufficient number of battery packs may be availableto properly discharge in order to power the end device.

If balancing is not required, the battery system may discharge to powerthe end device at block 717.

If balancing is required, the type of balancing is determined at block712. As will discussed in greater detail, embodiments may support threedifferent types of balancing: converter balancing (block 713), directbalancing (block 714), and staggered balancing (block 715).

Tables 1 and 2 present examples of balancing in accordance withembodiments.

TABLE 1 Example of Balancing Time Pack 1 Pack 2 Pack 3 Pack 4 Type T0100% 15%  15%  15%  Converter T1  85% 20%  20%  20%  Converter T2  65%32%* 32%  32%  Staggered T3  60% 38%  33%* 33%  Staggered T4  54% 39% 39%  34%* Staggered T5  49% 40%* 40%  40%  Staggered T6  45% 43%  41%*41%  Staggered Continue staggered balancing until completed Note: “*”denotes that the battery pack is being direct charged by Pack 1

TABLE 2 Example of Balancing Time Pack 1 Pack 2 Type T0 100% 15%Converter T1  85% 20% Converter T2  65% 32% Direct T3  60% 37% Direct T4 55% 42% Direct T5  48% 48% (Balancing Completed)

The above to examples illustrate that the type of balancing may changewhile the battery packs are being balanced. For example, with Table 1the balancing type changes from converter balancing to staggeredbalancing while with Table 2 the balancing type changes from converterbalancing to direct balancing.

After balancing, if the number of battery packs are available fordischarging, as determined at block 716, the end device may be poweredat block 717. Otherwise, the battery packs may be rebalanced based onthe revised SoC values obtained from the previous balancing.

When rebalancing occurs, as determined at block 716, the rebalancing mayutilize a different type of balancing than previously used. For example,converter balancing may be first applied while subsequent rebalancingmay utilize staggered balancing.

FIG. 7B expands on block 712 shown in FIG. 7A for determining the typeof charge balancing. For example, an embodiment may support a pluralityof balancing types such as direct balancing, converter balancing, andstaggered balancing as previously discussed.

At block 721, if the variability of the SoC values among the batterypacks is sufficiently small, the battery system is able to power the enddevice at block 722. (For example, the SoC differences between all pairsof battery packs is less than a predetermined threshold.) Otherwise,process 712 proceeds with balancing the battery packs.

Block 723 identifies the battery pack with the highest SoC value so thatthe identified battery pack can discharge, thus providing charge to theother battery packs during balancing.

At block 724 process 712 determines whether direct balancing cannot beapplied (for example, when the SoC difference between the highest SoCpack and an identified battery pack is above a predetermined SoCthreshold). If so, converter balancing is applied to the identifiedbattery pack (where the highest SoC battery pack discharges onto thepower bus and the identified battery pack charges through the power busvia its converter) at block 728. When converter balancing is completed,process 712 may revert back to block 721 and determine whether balancingcan be applied to a different combination of battery packs, where thebalancing type may be the same or may be different (for example, directbalancing or staggered balancing).

Referring back to block 724, if direct balancing can be applied (forexample, when the SoC difference between the highest SoC pack and theidentified battery pack is below the predetermined SoC threshold),process 712 determines whether converter balancing can be applied to oneor more other battery packs at block 725. If so, staggered balancing isapplied with the highest SoC pack, the identified pack, and the one ormore other packs at block 727. Otherwise, direct balancing is appliedbetween the highest SoC pack and the identified battery pack at block726.

FIG. 7C shows flowchart 700 for determining a balancing type for aplurality of battery packs in accordance with an embodiment.

Table 3 shows a relationship between an operational mode of a batterysystem and a safety interlock lock pin (indicator) and a wake pin(indicator). For example, the safety interlock pin is “On” when thebattery packs are properly inserted into the battery system (as sensedby an interlocking connection through the battery pack connectors), andthe wake pin is “On” when a user turns a key to activate a poweredappliance (end device).

TABLE 3 Mode of Operation Wake Pin Safety Interlock Pin Mode Off Off Off(Sleep) Off On Balancing On On Charging/Discharging On Off Off (Sleep)

When in the off (sleep) mode, the discharging and charging arrays of thebattery packs are disabled, and the battery packs consume only enoughelectrical power so that the battery pack may transition to anotherstate (for example, balancing mode) when the battery pack detects anappropriate signal (for example, a wake indicator).

With some of the embodiments, as shown in Table 3, a battery system maysupport a plurality of operational modes: Off (Sleep), Balancing, andCharging/Discharging. While a single mode is shown forcharging/discharging, charging and discharging are separate operationsbased on the interaction of the battery system with its externalenvironment. For example, when the wake and safety interlock indicatorsare on and if charger (typically external to the battery system) issensed via a CAN bus, the battery system enters the charging state.However, if the battery system senses an end device (for example, anappliance), the battery system enters the discharging state. As will bediscussed in further detail, a battery system may support “smartcharging” when in the charging mode and “smart discharging” when in thedischarging mode.

FIG. 7C is similar to 7A; however, process 730 includes an interactionwith sleep, balancing, and charging/discharging modes in accordance withthe relationship shown in Table 3. At block 731, when the safetyinterlock indicator is not detected, the battery system enters the sleepmode. Otherwise, the battery system (typically by the master batterypack) gathers configuration information (for example, SoC informationabout the different battery packs). At block 732, the battery systemdetermines whether the wake indicator is detected. If not, the batterysystem enters the balancing mode. Otherwise, the battery system entersthe charging/discharging mode.

FIG. 8 shows message flow scenario 800 for determining a balancing typefor a plurality of battery packs based on flowchart 700 and inaccordance with an embodiment. Master battery pack 802, based on theentries of the current confirmation list, confirms the availability ofbattery packs 803 and 804 at event 851 corresponding to messages 861 a,861 b, 862, and 863. As previously discussed, embodiments may supportdifferent messaging protocols. For example, with the CAN protocol a dataframe message may contain data in the data field that is indicative of aconfirmation request or a confirmation response. As previouslydiscussed, the interpretation of the data is in accordance with theapplication software executing at end device 801 and battery packs802-804.

End device 801 provides its power requirements in message 886 so thatmaster battery pack 801 can determine the number of battery packs neededfor end device 801 at event 852.

At event 853, master battery pack 802 gathers SoC data about the otherbattery packs via messages 865-868. (Master battery pack 802 may useinternal messaging within the battery pack to obtain SoC about itself.)For example, in accordance with the CAN protocol, data contained inRequest Pack Info message 865 may be interpreted as a request from thedestination battery pack while the data in Pack Info message 866 may beinterpreted as the requested data (for example, SoC data) from thedestination battery pack.

Based on the gathered SoC data, master battery pack 801 determines thetype of balancing required (if needed) and initiates the appropriatebalancing process (for example, processes shown in FIGS. 9, 11, and 13).

As previously discussed, embodiments may support different types ofbalancing, for example): converter balancing, direct balancing, andstaggered balancing. Converter balancing typically requires a longertime period than direct balancing.

While the processes shown in FIGS. 9, 11, and 13 are typically performedat the master battery pack, the master battery need not be changing ordischarging during balancing. This determination is based on the SoCvalues of battery cells 203 and 210 (shown in FIGS. 2A and 2B,respectively) and not on whether a battery pack is a master battery packor a slave battery pack.

FIG. 9 shows flowchart 713 (referenced in FIG. 7A) for converterbalancing with a plurality of battery packs in accordance with anembodiment. Block 901 starts converter balancing, where one of thebattery packs (either the master battery pack or one of the slave masterpacks) charges one or more of the other battery packs.

With converter balancing, charge of a single battery pack is transferredto one or more battery packs via converters on each of the chargedbattery packs. Consequently, two or more battery packs are involved withthis type of balancing.

While not explicitly shown, the master battery pack gathers SoC dataabout all of the battery packs, including itself. For example, themaster battery pack may request battery status information from theother battery packs via the CAN bus and internally obtain its own SoCdata.

At block 902, the master battery pack enables the battery pack with thehighest SoC for discharging by enabling the discharging array. Themaster battery pack also enables one or more of the battery packs withthe lowest SoC to accept the charge from the discharging battery pack byenabling the charging array and the on-board converter.

The master battery pack obtains SoC values from the above battery packsat block 904 and continues the balancing process at block 905 until adesired charge balance is obtained at block 905. If the charge balanceis sufficient, the battery pack may be used to power the end device.However, a faster mode of balancing (for example, direct balancing aswill be discussed) may be subsequently applied.

FIG. 10 shows a message flow scenario for converter balancing with aplurality of battery packs in accordance with an embodiment. Batterypacks 1002, 1003, and 1004 initially have SoC values of 100%, 65%, and65%, respectively. As previously discussed, master battery pack 1002 mayobtain the SoC values by requesting battery status information andreceiving the status information via data frame messages over a CAN bus.

At event 1051, master battery pack 1002 determines that packs 1003 and1004 are to be charged by itself (pack 1002). To do so, master batterypack enables its own discharging array and enables the charging arraysand converters via messages 1061 and 1062. Balancing continues until adesired balancing charge obtained (80%, 75%, and 75%) at event 1052. Atthat time, the balancing ends so that master battery pack disables itscharging array and disables the charging arrays and converters ofbattery packs 1003 and 1004 via messages 1063 and 1064.

FIG. 11 shows flowchart 714 for direct balancing with a plurality ofbattery packs in accordance with an embodiment. When process 700, asshown in FIG. 7A, determines that direct balancing should be performed,the master battery pack initiates direct balancing at block 1101.

With direct balancing, one of the battery packs is charging anotherbattery pack through a low impedance electrical path. Consequently, onlytwo battery packs are involved with type of balancing.

While not explicitly shown, the master battery pack obtains SoC valuesfor all installed battery packs in the battery system. In order to doso, the master battery pack sends status requests to the slave batterypacks and receives status information (for example, SoC values) from theslave battery packs via messaging on the communication channel. However,because the master battery knows about its own battery cell status, onlyinternal messaging for the master battery is needed.

At block 1102 the master battery pack instructs the battery pack withthe higher SoC to start discharging by enabling its discharging arrayand at block 1103 instructs one of the battery pack with the lower SoCto start charging by enabling its charging array.

At block 1104, the master battery pack gathers SoC data from the batterpacks being charge balanced. When an acceptable SoC is reached at block1105, direct balancing is terminated at block 1106.

FIG. 12 shows a message flow scenario for direct balancing with aplurality of battery packs in accordance with an embodiment. The masterbattery pack (pack 1201) gathers initial SoC values 80%, 70%, and 90%for battery packs 1201, and 1202, and 1203, respectively.

Because pack 1202 has the lowest SoC and pack 1203 has the highest SoC,the master battery pack instructs battery pack 1202 to enable itscharging array and battery pack 1203 to enable its discharging array viamessages 1261 and 1262, respectively.

When the SoC values of battery packs 1202 and 1203 reach 80%, the masterbattery pack (pack 1202) determines that direct balancing is competed atevent 1251 and consequently disables the charging array and thedischarging array via messages 1263 and 1264, respectively.

FIG. 13 shows flowchart 714 for staggered balancing with a plurality ofbattery packs in accordance with an embodiment. When process 700, asshown in FIG. 7A, determines that staggered balancing should beperformed, the master battery pack initiates staggered balancing atblock 1301.

Staggered balancing utilizes algorithmic direct balancing. Withstaggered balancing, one of the battery packs (typically the highest SoCvalue) direct charges another battery pack with a lower SoC whilecharges one or more other lower SoC battery packs through converterbalancing (where the converter located on the charged battery pack isenabled). In order to keep the other lower SoC battery packs within anacceptable range, direct balancing may switch to a different lower SoCbattery pack while the previous lower SoC battery pack is now converterbalanced.

At blocks 1301 and 1302, direct balancing is established with a batterypack with the highest SOC with another battery pack in the group with alow SoC similar to blocks 1101 and 1102 as shown in FIG. 11. However,converter balancing is established with some or all of the battery packsin the low SoC group at block 1304.

At block 1305, the master battery pack gathers the updated SoC values ofthe participating battery packs. When the battery pack being directedcharge reaches a determined SoC threshold (for example, when animbalance occurs one of the battery packs in the low SoC group), directbalancing is established with another battery pack in the low SoC groupat block 1307.

When all of the battery packs are within an acceptable SoC range, asdetermined at block 1308, staggered balancing is terminated at block1309.

FIGS. 14-15 show a message flow scenario for staggered balancing with aplurality of battery packs in accordance with an embodiment. The masterbattery pack (pack 1401) gathers initial SoC values 60%, 60%, and 100%at battery packs 1401, and 1402, and 1403, respectively.

At event 1451, master battery pack 1401 initiates direct balancingbetween battery packs 1402 (in the low SoC group) and 1403 (the highestSoC) and to establish converter balancing between battery 1403 anditself (also in the low SoC group). Consequently, master battery pack1401 sends messages 1461 and 1462, corresponding to battery packs 1461and 1462, respectively, over the communication channel and to generateany internal messaging, as necessary, to enable its charging array andconverter.

As a result of the balancing, the SoC values of battery packs 1401,1402, and 1403 change to 62%, 70%, and 88%, respectively. Because of thecharge imbalance between battery packs 1401 and 1402, master batterypack 1401 establishes direct balancing between battery pack 1403 anditself and establishes converter balancing for pack 1402. Consequently,at event 1452, master battery pack 1401 instructs battery pack 1402 toenable its converter (so that charging occurs now via the converterrather than directly) via message 1463 and to disable its own converterso that its battery cells are directly exposed to charging.

Referring to FIG. 15, as a result of the balancing, the SoC values ofbattery packs 1401, 1402, and 1403 change to 72%, 72%, and 76%,respectively. At event 1453, master battery pack 1401 determines thatbalancing has completed and terminates the staggered balancing bysending messages 1464 and 1465 to battery packs 1403 and 1402,respectively, and internally disables its charging array.

Referring to FIG. 15, as a result of the balancing, the SoC values ofbattery packs 1401, 1402, and 1403 change to 72%, 72%, and 76%,respectively. At event 1453, master battery pack 1401 determines thatbalancing has completed and terminates the staggered balancing bysending messages 1464 and 1465 to battery packs 1403 and 1402,respectively, and internally disables its charging array.

Intelligent systems and algorithmic methods (for example, process 1700as shown in FIG. 17) may ensure that SoC's corresponding to theplurality of battery packs may become more balanced, e.g., to ensurethat the plurality of battery packs can be charged together. In variousembodiments, a battery pack may include one or more batteries and/or maycomprise a device that may include one or more batteries. The one ormore batteries of a battery pack may share various characteristics(e.g., a state of charge, a state of health, etc.). Furthermore, eachbattery pack can be enabled or disabled, e.g., in their ability tocharge or discharge other battery packs or end devices.

Still referring to FIG. 16, battery packs that have a large SoCvariation may not be immediately connected with charger 1601. Forexample, as shown in FIG. 16, battery packs 1602 a and 1603 a, whicheach have lower SoC's (e.g., 20% and 20%, respectively) than otherbattery packs, may be charged earlier (e.g., before the other batterypacks) until a set threshold can be reached at which a batter pack witha higher SoC (e.g., battery pack 1604 b) can be charged. Prioritizingthe charging of battery packs with lower SoC's before the charging ofbattery packs with higher SoC's may be necessary, e.g., becauseotherwise, charging the higher battery pack with the higher SoC firstmay cause a fast in-rush electrical current to the lower SOC pack. Insome aspects, systems and devices presented herein may cause thecharging of the various battery packs by enabling the flow of electricdischarge arrays between a charger and the respective battery packs.

As shown in FIG. 16, initially charging battery packs 1602 a and 1603 acauses their SoC's to increase from 20% to 40% (e.g., as shown in 1602 band 1603 b). Charging may continue for battery packs 1602 b-1604 b untilthe SoC level of battery pack 1605 b is reached. At that point, batterypack 1605 b may be enabled so that charging can continue for batterypacks 1602 b-1605 b.

FIG. 17 shows an example flowchart of a method 1700 for charging aplurality of battery packs in accordance with an embodiment. Method 1700may be performed by a computing device having one or more processors,which may be communicatively linked to one or more of the plurality ofbattery packs and/or to the charger. Also or alternatively, thecomputing device performing method 1700 may comprise a battery pack(e.g., a “master battery pack” or a “master battery pack”) that has acapability of managing one or more functions of other battery packs ofthe plurality of battery packs. After obtaining the SoC values of thebattery packs in a battery system, a subset of the battery packs may begrouped into a lower SoC group at block 1701. For example, the obtainedSoC values (e.g., SoC readings) may be sorted into various levels, e.g.,based on predetermined ranges. Those battery packs having the lowest SoCvalues may be grouped into the lowest level. Battery packs within aspecified level may have SoC values that are within a specified orpredetermined range of one another. Those battery packs having thesecond lowest of SoC values (e.g., SoC values that are higher than thoseof the lowest level but lower than the rest of the battery packs) may beplaced into the second lowest level. As used herein, a “Lower SoC Packs”may refer to the battery packs of a list comprising (1) the group ofbattery packs of the lowest level of SoC values and (2) the group ofbattery packs of the second lowest level of SoC values.

At block 1702, an SoC threshold may be determined. The SoC threshold maybe approximately equal to the SoC value of the group of one or morebattery packs having SoC values just above the group of battery packswith the lowest SoC values. For example, the SoC threshold may be basedon the SoC values of the second lowest level (e.g., an average of theSoC values of the battery packs of the second lowest level).

The battery packs of the group with the lowest levels of SoC can beenabled for charging at block 1703, e.g., facilitating the charging ofthe battery packs having the lowest level of SoC. In some aspects, thecharging may be enabled if one or both of the safety interlock pin orthe wake pin is set to “on,” as discussed previously.

When the SoC values of the charged battery packs reach the SoCthreshold, as determined at block 1704, process 1700 may includedetermining whether to enlarge the list (e.g., the “Lower SoC Packs”list of step 1701) for subsequent charging at block 1705. Thedetermination of whether to enlarge the list may be based on whetherthere is significant variability in to SoC of the battery packs (e.g.,whether the SoC variability of the battery packs satisfies an SoCvariability threshold), as will be described further in relation to FIG.18C. If the list is to be enlarged, the SoC threshold may be updated(e.g., based on determining the second lowest level of SoC's in theupdated list), the selected battery packs may be enabled, and chargingmay continue at blocks 1706 and 1707.

FIG. 18A shows a message flow scenario for charging a plurality ofbattery packs for the example shown in FIG. 16. In this scenario,charger 1801 a may perform one or more iterations of gathering SoC data(e.g., receive SoC readings) from a plurality of battery packs (e.g.,battery packs 1802 a-1805 a), identifying SoC levels to form lists basedon the SoC levels, and enabling the charging of selected battery packsto SoC thresholds via the communication channel (for example, a CANbus). For example, at event 1851 a, charger 1801 a may gather initialSoC values 20%, 20%, 40%, and 60% from battery packs 1802 a, 1803 a,1804 a, and 1805 a, respectively.

At event 1851 b, charger 1801 a may determine that the group of batterypacks with the lowest level of SoC values includes battery packs 1802 aand 1803 a, and that the group of battery packs with a higher (e.g.,second lowest) level of SoC values includes battery pack 1804 a. A listof battery packs may be formed and may include the battery packs at thelowest levels of SoC and the battery pack at the higher (e.g., secondlowest level).

At event 1851 c, the charger 1801 a may enable the charging of group ofthe battery packs with the lowest level of SoC values (e.g., batterypacks 1802 a and 1803 a) via messages 1861 and 1862. Charging maycontinue until the SoC values for these battery packs satisfy an SoCthreshold based on a group of one or more battery packs having higherSoC values (e.g., the battery pack having the second lowest level of SoCvalues (e.g., battery pack 1804 a at 40%)).

At event 1852 a, the charger 1801 a may gather SoC values for all packs.As shown in FIG. 18A, the SoC values for battery packs 1802 a and 1803 awill have increased to 40% as a result of the aforementioned charging atevent 1851 c. At event 1852 b, charger 1801 a may determine to expandthe list of battery packs determined at event 1851 a. For example, anSoC variability may be determined for battery packs 1802 a-1805 a, andthe list may be expanded based on the SoC variability being significantenough to satisfy a SoC variability threshold. In the scenario depictedin FIG. 18A, battery pack 1806 a has an SoC value of 60%, which isdifferent from the updated SoC value if 40% for battery packs 1802 a,1803 a, and 1804 a. Thus, battery packs 1802 a, 1803 a, 1804 a, and 1805a exhibit SoC variability, which may cause the charger 1801 a to enlargethe list. The enlarged list may include an updated group of one or morebattery packs with the lowest level of SoC values (e.g., battery packs1802 a, 1803 a, 18004 a) and an updated group of one or more batterypacks with a higher level of SoC values (e.g., battery pack 1805 a). Theformer group (e.g., the group of battery packs with the lowest level ofSoC values) may thus include battery pack 1804 a. At event 1852 c, thecharger 1852 c may thus enable the charging of battery packs 1802 a,1803 a, and 1804 a via message 1863.

FIG. 18B shows an example message flow scenario for charging a pluralityof battery packs for the example shown in FIG. 16. However, rather thancharger 1801 b gathering SoC data and enabling the battery packs, masterbattery pack 1802 b does so when charger 1801 b is detected viaconnection indicator 1871. Connection indicator 1871 may be obtained bydifferent approaches, including messaging over a communication channel,a pin, and so forth.

FIG. 18C shows an example flowchart of a method 1800C for intelligentlycharging a plurality of battery packs, in accordance with a non-limitingembodiment. Method 1800C may be performed by a computing device havingone or more processors. The computing device may be a standalone devicecommunicatively linked to one or more of the battery packs and/or to thecharger. Also or alternatively, the computing device may comprise one ofthe battery packs (e.g., a master battery pack) that has the capabilityof managing one or more functions of the other battery packs of theplurality of battery packs. Also or alternatively, the computing devicemay comprise the charger.

As discussed previously, each battery pack may have a state of charge(SoC) indicating, e.g., a degree or level of charge relative to itscapacity. At step 1874, the computing device may receive a reading(e.g., first reading) of the SoC of each of the plurality of batterypacks. The reading may be obtained via a sensor or a monitor at eachbattery pack. As discussed previously, the SoC's may vary among aplurality of battery packs or may remain relatively constant. An SoCvariability (e.g., a first SoC variability) may be computed to indicatea degree of variability of the SoC of the plurality of battery packs(e.g., as in step 1875).

The SoC variability may be based on the SoC's of each of the respectivebattery packs obtained in step 1874. For example, an SoC variability maybe based on one or more of a variance, a standard deviation, a range(e.g., an interquartile range), a mean absolute difference, a medianabsolute deviation, an average absolute deviation, a distance standarddeviation, or a like metric based on the SoC values of each of theplurality of battery packs. For example, in Table 1 discussed above,which comprises a plurality of battery packs (e.g., Pack 1, Pack 2, Pack3, and Pack 4), there is greater SoC variability at time T0 than thereis at time T6. In one aspect, where SoC variability is determined on thebasis of a computed range of SoC values, the SoC variability of thebattery packs at TO is 85 (i.e., 100%-15%), whereas the SoC variabilityat T6 is only 4 (e.g., 45%-41%). If “5” is set as an SoC variabilitythreshold, then the SoC variability at T6 may be said to have satisfied(e.g., fall below) the threshold.

In some aspects, before the computing device can receive the SoCreadings, an interlock safety pin may need to allow interaction with thebattery packs to occur. For example, the computing device may initiallydetermine that the interlock safety pin allows the receiving the SoCreadings from the plurality of battery packs.

The computing device may store, e.g., in memory device 202, a metricindicating an SoC's variability threshold, e.g., to indicate whethervariability of the SoC's is insignificant. For example, if an SoC of abattery pack (e.g., first battery pack) is significantly lower than anSoC of another battery pack (e.g., a second battery pack), it is likelythat the SoC variability will be significant and therefore not satisfythe SoC variability threshold. At step 1876, the computing device maythus determine whether the SoC variability (e.g., as computed in step1875) satisfies the SoC variability threshold.

If the SoC variability does not satisfy the SoC variability threshold(e.g., the variation in SoC's among the plurality of battery packs issignificant) the computing device may establish an SoC threshold (e.g.,as in step 1878) The SoC threshold may be based on the SoC reading ofbattery pack having the next higher SoC reading (e.g., the secondbattery pack) after the battery pack with the lowest SoC (e.g., thefirst battery pack). Thus, the computing device may identify the lowestSoC readings in order to determine the next higher SoC reading (e.g., asin 1877). For example, as discussed in relation to FIG. 16, battery pack1604 a had an SoC of 40%, which is the next higher SoC after the lowestSoC of the battery packs of 20% belonging to battery packs 1602 a and1603 a. Thus, based on the example show in relation to FIG. 16, an SoCthreshold may be set to 40%.

Furthermore, at step 1879, the computing device may cause the chargingof battery packs that have lower SoC's than the established SoCthreshold, e.g., by enabling electric charge arrays from the charger tothe battery packs. The charging may cause the SoC's of the battery packsto increase, e.g., so that it approaches, matches, and/or satisfies theSoC threshold.

In some aspects, before the computing device can cause the charging ofany battery packs, a wake pin, as discussed previously, may need toallow for the charging to occur. For example, the wake pin may need tobe set to “on” before a charging can occur. The computing device mayinitially determine that the wake pin is set to “on” before causing thecharging of the battery packs.

This can be detected by the computing device via an additional reading(e.g., a second reading) of the SoC's of each of the plurality ofbattery packs. Furthermore, the computing device may determine orcompute, based on the additional reading, a second SoC variability ofthe plurality of battery packs. The second SoC variability may be foundto satisfy the SOC variability threshold.

If the second SoC variability is not found to satisfy the SoCvariability threshold, one or more steps of method 1800C may be repeateduntil the SoC variability threshold is satisfied. For example, a new SoCthreshold may be set based on the next higher SoC after the lowest SoC,and causing the charging of the battery packs with the lowest SoC's.

Thus, one or more iterations of the following can be performed after anupdated SOC variability of the plurality of battery packs satisfies theSOC variability threshold: The computing device may identify an Nthgroup of one or more battery packs within the plurality of battery backdevices, wherein the Nth group may have the lowest level of a previousreading of the SOC of the plurality of battery packs; the computingdevice may also identify an (N+1) group of one or more battery packs ofthe plurality of battery back devices, wherein the (N+1) group can havethe second lowest level of the previous reading of the SOC of theplurality of battery packs; and the computing device may generate a listcomprising the n group and the N+1 group. In each iteration, thecomputing device may determine that the SOC variability of the list inthe current iteration does not satisfy the SOC variability threshold. Ifthe SoC variability does satisfy the SoC threshold, the computing devicemay exit the iterations loop. However, assuming the SoC variability ateach iteration does not satisfy the SoC variation threshold, thecomputing device may an SOC threshold using the previous reading of theSOC of the N+1 group. Subsequently, the computing device may cause, viaelectric charge arrays, the charging of the N group of battery packs tocause the SOC of the N group to increase and satisfy the SOC threshold.The computing device may receive a subsequent reading of an SOC of eachof the plurality of battery packs. An updated SoC variability of theplurality of battery packs may thus be determined based on thesubsequent reading of the SoC of each of the plurality of battery packs.As discussed, the above steps may be repeated until the SoC variability(updated at each iteration) satisfies the SoC variability threshold(e.g., the SoCs of the battery packs vary less than a specified range).

The following FIG. 19A and FIG. 19B show two examples of a batterysystem powering an end device based on power requirements of the enddevice. In FIG. 19A, only one battery pack is needed to power end device1901 a, b while in FIG. 19B, more than one battery pack is needed topower end device 1911 a, b.

FIG. 19A shows an example of a plurality of battery packs discharging inorder to electrically power an end device in accordance with anembodiment. The initial SoC values of battery packs 1902 a-1905 a are40%, 40%, 40%, and 60%, respectively. As shown in FIG. 19A, a singlebattery pack (e.g., battery pack 1905 a having an SoC of 60%) mayinitially be used to power end device 1901 a until the SoC value of thesingle battery pack reaches 40% (the same SoC values as the otherbattery packs) (e.g., as in battery pack 1905 b). Using only a group ofone or more battery packs having the highest or higher SoC level (inthis case the single battery pack 1905 a) to initially power an enddevice, until the SoC values of the group reaches those of the rest ofthe pack, may be a more efficient and/or safe method of utilizingbattery packs to power an end device. As shown in FIG. 19A, after thesingle battery pack with the initially higher SoC value has been used toinitially power the end device, and its SoC readings reach those of theother battery packs (e.g., battery packs 1902 b-1905 b), the otherbattery packs may join in powering the end device 1901 b.

FIG. 19B shows another example of a plurality of battery packsdischarging in order to electrically power an end device in accordancewith an embodiment. As shown in FIG. 19B, the initial SoC values ofbattery packs 1912 a-1915 a are 40%, 40%, 40%, and 60%, respectively. Insome aspects, more than one battery pack may be needed to power enddevice 1911 a-b. In such aspects, various systems and methods presentedherein may be used to balance the battery packs before powering enddevice 1911 a-b. The balancing of battery packs 1912 a-1914 a may beperformed, e.g., to safeguard against the risk of an undesiredelectrical current in-rush from battery pack 1915 a, which may occur inthe absence of the balancing. When balancing is achieved, battery packs1912 b-1915 b can then power end device 1911 b.

When powering an end device (for example, a machine), connecting batterypacks with varying SoC's may be problematic. Consequently, to preventsuch problematic situations, a process (often implementing anintelligent method) may be needed to ensure that a required number ofbattery packs are connected for system discharge and enabled whenappropriate.

Typically, when multiple battery packs are needed to power an enddevice, it may be advisable for battery packs with large SoC variationsto not be connected at the same time. Rather, balancing of the batterypacks may be performed initially.

Discharging may use one or more battery packs with higher SoC valuesfirst until passing a set threshold for lower SoC battery packs, atwhich point the lower SoC battery packs may be enabled.

Processes 2000 and 2010 shown in FIGS. 20A and 20B, respectively, arebased on the above guidelines.

FIG. 20A shows process 2000 for discharging a plurality of battery packsin order to power an end device. At blocks 2001-2003, initial SoC valuesof the battery packs are gathered and balancing may be performed basedon the SoC variation and the power requirements of the end device. FIG.19B, as discussed previously, is an example illustration of the processof balancing the battery packs, as described in blocks 2001-2003.However, as will be described in blocks 2004-2008, some aspects of thepresent disclosure may involve the initial powering of an end device bya single or limited number of battery packs having a higher SoC level,before other battery packs can join in the powering of the end device.FIG. 19a , as discussed previously, is an example illustration of theprocess of powering an end device by a limited number of battery packsinitially and expanding the list of battery backs that can power the enddevice.

Referring now to block 2001 a, a power requirement of the end device maybe obtained, and a first reading of a SoC of each of the plurality ofbattery packs may be obtained. The plurality of battery packs mayinclude various battery packs or groups of battery packs with varyingSoC values. At block 2001 b, an SOC variability may be calculated todetermine a degree to which the SoC values vary among the plurality ofbattery packs. Also or alternatively, the highest SoC level may beidentified, and the computing device may determine that not all of thebattery packs have SoC values the highest SoC level.

Depending on the SoC variability, the plurality of battery packs maypose a risk if they are used to concurrently power the end device. Asdiscussed previously in relation to FIG. 19a , if a group of one or moreof the plurality of battery packs has SoC values at a level that issignificantly greater than the SoC's of the rest of the plurality ofbattery packs, it may be advisable to initially power the end deviceonly using the group with the significantly greater SoC values (e.g.,without the concurrent powering by the other battery packs of theplurality of battery packs). The computing device may allow a group of asingle or a restricted number of battery packs to power an end device byonly enabling the corresponding discharge arrays of the group. Thepathway of allowing the group to power the end device is shown in blocks2004-2008.

Another way to address the above-described and similar risks may be tobalance the battery packs, and thereby reduce the SoC variability of theplurality of battery packs, as discussed previously in relation to FIG.19b . For example, one group of battery packs (e.g., a first group) mayhave SoC values that are at a level lower than another group of batterypacks (e.g., a second group). An SoC variability of the plurality ofdevices may be calculated and found to not satisfy an SoC variabilitythreshold (e.g., the range between the highest and lowest SoC values istoo high) based on the variation in SoC between the first group andsecond group. The computing device may thus determine that a balancingis required (e.g., “Yes” at block 2002) based on the SoC variability notsatisfying (e.g., falling within) the SoC variability threshold. Thebattery packs may thus be balanced according to previously discussedmethods as shown in FIG. 19B.

The computing device may consequently determine whether or not abalancing is not required (e.g., “No” at block 2002). The decision maybe a preference provided (e.g., configured) to the computing device byan operator of the computing device. Also or alternatively, the decisionmay be based on two or more SoC variability thresholds. For example, ifthe SoC variability of the plurality of battery packs is higher than ahigher SoC variability threshold (e.g., a first SoC variabilitythreshold), the pathway of balancing the battery packs may be triggered.If the SoC variability is not higher than the first SoC variabilitythreshold but is still higher than a second SoC variability threshold(which is not as high as the first SoC variability threshold), thepathway depicted in bocks 2004-2008 may be triggered (e.g., causingbattery pack(s) with higher SoCs to initially power the end device).

Referring now to blocks 2004-2005, a group of one or more battery packsmay be identified and enabled (e.g., by enabling the correspondingdischarge arrays) to power the end device. The group may be identifiedby identifying the battery packs with SoCs at the highest level, or atleast at a higher level than other battery packs. The computing devicemay thus cause the group to power the end device, thereby beginning thedischarging of the group of battery packs (e.g., as in block 2005). Thegroup of discharging battery packs may reach an lower SoC level. Theresulting lower SoC level of the group, which initially had a higher SoClevel, may result in a lower SoC variability for the plurality ofbattery packs. The computing device may thus determine the updated SoCvariability at block 2006. If the updated SoC variability fails tosatisfy the SoC variability threshold (e.g., there are still batterypacks with higher SoC levels), the additional battery packs may besimilarly identified and enabled to power the end device at blocks2004-2005. After the SoC variability of the plurality of battery packssatisfies the SoC variability threshold (e.g., there is not muchvariation in the SoC levels of the plurality of battery packs), thecomputing device may allow all battery packs to power the end device.

Also or alternatively, both of the above-described pathways (e.g.,blocks 2002-2003 and blocks 2004-2008, respectively) may be combined.For example, after balancing has been performed at block 2003, a secondreading of the SoC's of each of the plurality of battery packs may beobtained, and a second SoC variability may be calculated. The SoCvariability may satisfy the SoC variability threshold, e.g., the SoC'sof the plurality of battery packs may vary less and/or have a reducedrange. Subsequently, the plurality of battery packs may concurrentlypower the end device.

FIG. 20B shows process 2010 for discharging a plurality of battery packsin accordance with an exemplary embodiment. Process 2010 is similar toprocess 2000; however, some of the battery packs may be sequesteredbased on a state of health (SoH) of the battery packs. Battery packswith a low SoH may be sequestered and used only when needed.

At blocks 2011-2013, the SoC and SoH values of the battery packs may begathered. The battery packs with SoH values that do not satisfy apredetermined SoH threshold may be sequestered, and in order to enabledafter non-sequestered battery packs have been used. Non-sequesteredbattery packs (e.g., battery packs with SoH levels that satisfy the SoHthreshold) may be used to initially power the end device based on theend device requirements and SoC values of the battery packs, asexplained herein.

For example, at block 2013, the battery packs with SoC values thatsatisfy an SoC threshold (e.g., the SoC values are above the nexthighest level of SoC among the plurality of battery packs) may beenabled to power an end device, thereby resulting in the discharging ofthese battery packs at block 2014. As shown in blocks 2014-2016, theenabled battery packs can be discharged until a lower SoC value isreached (e.g., the SoC fail to satisfy the SoC threshold). At that time,additional non-sequestered battery packs may be enabled at block 2017.However, when no non-sequestered battery packs are available, thesequestered battery packs may be considered at 2018-2020.

Sequestering low SoH battery packs may be beneficial since usage ofolder battery packs (often associated with a low SoH value) may bereduced, thus extending the life of those battery packs.

FIG. 21 shows a message flow scenario for discharging a plurality ofbattery packs for the example shown in FIG. 19A. Battery packs 2002-2005initially have SoC values of 40%, 40%, 40%, and 60%, respectively. Powerrequirements of end device 2101 may be obtained from master battery pack2102 via message 2161 over the communication channel (for example, a CANbus), where only one battery pack is needed to power end device 2101.Consequently, in accordance with process 2100, master battery pack 2102may enable battery pack 2105 for discharging via message 2162.

When battery pack 2105 reaches the SoC value of the other battery packs,master battery pack 2102 enables battery packs 2103 and 2104 viamessages 2163 and 2164 and may enable itself via internal messaging.

In some aspects, a process (for example, process 2200 as will bediscussed) may be directed to a “limp home mode” operation for a failedLi-ion battery cell in a large-format battery pack system. A “Limp homemode” operation can safely mitigate a catastrophic failure in a system.For example, the voltage of a battery cell may become very low (e.g.,below a predetermined voltage threshold), indicative of a failingbattery cell. With a medium-large battery pack implementation, theinternal battery management system may preemptively diagnose a failureand consequently may mitigate the failure by initiating a partialshutdown of the battery pack such that the equipment (end device) beingpowered by the battery system does not require a total shutdown and canstill “limp home.”

FIG. 22 a flowchart for limp home mode operation in accordance with anembodiment. At block 2201, the master battery pack detects acatastrophic failure of one or more of the battery cells of one of thebattery packs powering the end device. For example, a cell voltage inthe battery pack may drop below an acceptable minimum threshold, amaximum current is exceeded, and/or a battery cell temperature is abovean allowable range.

When the master battery pack detects the catastrophic failure, themaster battery pack determines whether an extra battery pack is neededat block 2202. For example, a battery system may have activated fourbattery packs when an end device needs only three battery packs with agiven SoC level. If so, process 2200 disables the bad battery pack andcontinues operation at block 2203.

However, if the extra battery pack is needed, the master battery packdetermines whether an unused battery pack (which may be the masterbattery pack itself) in the battery system is available at block 2204.If so, the master battery pack disables the bad battery pack (forexample, disabling the discharging array) and enables the extra batterypack (for example, enabling the discharging array) at block 2205. Ifmore than one extra battery pack is available, the master battery packmay select the extra battery pack having the largest SoC value in orderto continue service for the largest possible time. However, when noextra battery packs are available and degraded operation of the enddevice is permitted, as determined at block 2206, the master batterypack disables the bad battery pack and sends a failure alert message tothe end device about degraded operation at block 2208. However, ifdegraded operation is not acceptable for the end device, power isremoved from the end device at block 2207 to shut down the end device.

When a fault occurs at a slave battery pack, it is possible that theslave battery pack does not send a message to the master battery packunder various failure modes. However, the master battery pack maydetermine that there is no longer communication from the slave batterypack and adjust a power level (derate) to the end device.

While the bad battery pack may be a slave battery pack, the masterbattery pack itself may be the bad battery pack. For example, a faultmay occur with one of its battery cells while the processingcapabilities of the master battery pack is not compromised. If so, themaster battery pack may internally disable its own discharging array,attempt to enable the discharging array of a spare battery pack, andcontinue operating as the master battery pack.

With some embodiments, when the master battery pack has faulted, a newmaster battery pack may be assigned even if the faulty master batterypack is still operational. This approach ensures that the faulty masterbattery pack does not compromise the integrity of the overall handlingof the other battery packs.

With some embodiments, when the master battery pack has faulted, a newmaster battery pack may be assigned to allow continued deratedperformance when communication to the faulty master battery is lost.

FIG. 23A shows a message flow scenario for limp home mode operation inaccordance with an embodiment. With this scenario, a spare battery pack(pack 2104 a) is available when a catastrophic failure is detected atbattery pack 2103 a.

At event 2151 a, master battery pack 2102 a detects a catastrophicfailure at battery pack 2103 a in response to failure notificationmessage 2161. For example, battery pack 2103 a may provide batterystatus information indicative of a low battery cell voltage. The statusinformation may be in response to a query from master battery pack 2102a or may be autonomously sent when a catastrophic event occurs.Consequently, master battery pack 2102 a enables spare battery pack 2104a and disables bad battery pack 2103 a via messages 2163 and 2162,respectively.

FIG. 23A shows a message flow scenario for limp home mode operation inaccordance with an embodiment. With this scenario, a spare battery packis not available.

At event 2152, similar to the message scenario in FIG. 23A, masterbattery pack 2102 b detects a catastrophic failure at battery pack 2103b when receiving failure notification message 2164 from 2103 b. Becausemaster battery pack 2102 b determines that no spare battery pack isavailable, master battery pack 2102 b disables battery pack 2103 b viamessage 2165 and sends degradation message 2166 to end device 2101 b,where end device 2101 b is able to operate in a degradation mode.

Referring to FIGS. 23A-B. failure notification messages 2161 and 2163may be autonomously sent from the battery pack incurring thecatastrophic failure or may be sent in response to a request for batterystatus information from master battery pack 2102 a,b. When sentautonomously, the battery pack may detect when a battery parameter (forexample, SoH or cell voltage) drops to a predetermined threshold andthen sends the failure notification message to master battery pack 2102a,b. When sent in response to a status request, master battery pack 2102a,b, the status request repetitively (for example, periodically). Thebattery pack receives the status requests and, in response, providescurrent battery status information. When one or more of the returnedbattery parameters drops below a predetermined threshold, master batterypack 2102 a,b detects a catastrophic failure at the battery pack.

With some embodiments, master battery pack 2102 a,b may receive periodicbattery status information from the other battery packs. When masterbattery pack 2102 a,b detects a sudden drop (for example, more than apredetermined difference with respect to the previous value) in one ofthe battery parameters (for example, cell voltage), master battery pack2102 a,b may determine that a catastrophic failure at the correspondingbattery pack is predicted or imminent and take preemptive action and/orgenerate a warning notification.

With some embodiments, battery cells 203 and 210 (shown in FIGS. 2A and2B, respectively) may have a cell structure (for example, a parallelstructure) so that the battery pack may deactivate the failing batterycells while the other battery cells remain enabled. In such a situation,the battery pack may operate in a degraded mode and report that thebattery pack is operating in the degraded mode to master battery pack2102 a,b.

Many illustrative embodiments are listed below in accordance with one ormore aspects disclosed herein. Although many of the embodiments listedbelow are described as depending from other embodiments, thedependencies are not so limited. For example, embodiment #5 (below) isexpressly described as incorporating the features of embodiment #1(below), however, the disclosure is not so limited. For example,embodiment #5 may depend any one or more of the preceding embodiments(i.e., embodiment #1, embodiment #2, embodiment #3, and/or embodiment#4). Moreover, that any one or more of embodiments #2-#12 may beincorporated into embodiment #1 is contemplated by this disclosure.Likewise, any of embodiments #1, 14, 17, 22 may be combined with one ormore of the features recited in embodiments #2-13, 15-16, 18-21, and/or23-26. Further likewise, any of embodiments #27, 39, 43 may be combinedwith one or more of the features recited in embodiments #28-38, 40-42,44-46. Further likewise, any of embodiments #47, 59, 64 may be combinedwith one or more of the features recited in embodiments #48-58, 60-63,65-69. Further likewise, any of embodiments #70, 87, 92 may be combinedwith one or more of the features recited in embodiments #71-86, 88-91,93-94. Further likewise, any of embodiments #95, 105, 109 may becombined with one or more of the features recited in embodiments#96-104, 106-108, 110-114. In addition, that any one or more of thefeatures in embodiments #1, 14, 17, 22, 27, 39, 43, 47, 59, 64, 70, 87,92, 95, 105, and 109 may be combined is contemplated by this disclosure.Moreover, that any one or more of the features in embodiments #1-114 canbe combined is contemplated by this disclosure.

Embodiment #1. A first battery pack configured for installation in abattery system for electrically powering an end device, wherein allinstalled battery packs installed in the battery system havesubstantially identical electrical and electronic components, the firstbattery pack comprising:

-   -   a communication interface circuit configured to interface to a        communication channel;    -   a power bus interface circuit configured to interface with a        power bus and to provide electrical power to the end device;    -   a controller comprising at least one processor; and    -   a memory storing controller instructions that, when executed by        the at least one processor, cause the controller to:        -   obtain a configuration list of installed battery packs in            the battery system, wherein a first entry corresponds to the            first battery pack;        -   when the first entry of the configuration list has a top            priority position in the configuration list, configure the            first battery pack to serve as a master battery pack of the            battery system, wherein the top priority position is            indicative that the first battery pack was installed before            any other active battery packs in the battery system;        -   revise the configuration list when a second battery pack is            installed or removed from the battery system; and        -   repetitively broadcast the configuration list to all said            installed battery packs over the communication channel via            the communication interface circuit.

Embodiment #2. The first battery pack of Embodiment #1, wherein thecontroller instructions, when executed by the at least one processor,further cause the controller to:

-   -   when a third battery pack is added to the battery system, detect        an insertion of the third battery pack; and    -   create a third entry for the third battery pack in the        configuration list, wherein the third entry is at a bottom        position of the configuration list.

Embodiment #3. The first battery pack of Embodiment #2, wherein thecontroller instructions, when executed by the at least one processor,further cause the controller to:

-   -   when the second battery pack is removed from the battery system,        detect removal of the second battery pack; and    -   delete a second entry for the second battery pack in the        configuration list.

Embodiment #4. The first battery pack of Embodiment #3, wherein thecontroller instructions, when executed by the at least one processor,further cause the controller to:

-   -   advance a list position of the third entry for the third battery        pack in the configuration list.

Embodiment #5. The first battery pack of Embodiment #1, wherein thecontroller instructions, when executed by the at least one processor,further cause the controller to:

-   -   when the first entry for the first battery pack is not at the        top priority position in the configuration list, configure the        first battery pack to serve as a first slave battery pack.

Embodiment #6. The first battery pack of Embodiment #5, wherein thecontroller instructions, when executed by the at least one processor,further cause the controller to:

-   -   when another battery pack is removed from the battery system and        the first entry moves to the top priority position of the        configuration list, configure the first battery pack to serve as        the master battery pack.

Embodiment #7. The first battery pack of Embodiment #1, wherein thecommunication channel comprises a controller area network (CAN) bus andwherein the controller instructions, when executed by the at least oneprocessor, further cause the controller to:

-   -   utilize a SAE J1939 Address Claim Procedure to obtain an        identification (ID) for the first battery pack, wherein the ID        is included in the first entry.

Embodiment #8. The first battery pack of Embodiment #5, wherein thecontroller instructions, when executed by the at least one processor,further cause the controller to:

-   -   when the first battery pack serves as the first slave battery        pack:        -   receive a first request from the master battery pack; and        -   in response to the receiving the first request, respond to            the first request from the master battery pack.

Embodiment #9. The first battery pack of Embodiment #1, wherein thecontroller instructions, when executed by the at least one processor,further cause the controller to:

-   -   when the first battery pack serves as the master battery pack:        -   send a second request to a second slave battery pack; and        -   in response to the sending, receive a response message from            the second slave battery pack.

Embodiment #10. The first battery pack of Embodiment #1, wherein thecontroller instructions, when executed by the at least one processor,further cause the controller to:

-   -   when the first battery pack is removed from the battery system        and reinserted into the battery system, send a join request over        the communication channel; and    -   receive the configuration list with a fourth entry at a bottom        position in the configuration list, wherein the fourth entry is        associated with the first battery pack.

Embodiment #11. The first battery pack of Embodiment #1, the firstbattery pack comprising non-volatile memory and wherein the controllerinstructions, when executed by the at least one processor, further causethe controller to:

-   -   store battery pack information in the non-volatile memory; and    -   when the first battery pack is removed from the battery system        and reinserted tin to the battery system, retain the battery        pack information.

Embodiment #12. The first battery pack of Embodiment #2, wherein thecontroller instructions, when executed by the at least one processor,further cause the controller to:

-   -   when the first battery pack serves as the master battery pack:        -   send a repetitive broadcast message to all said installed            battery packs over the communication channel via the            communication interface circuit; and        -   when a repetitive broadcast message is not received from the            third battery pack, remove the third entry from the            configuration list.

Embodiment #13. The first battery pack of Embodiment #12, wherein therepetitive broadcast message is sent periodically and wherein thecontroller instructions, when executed by the at least one processor,further cause the controller to:

-   -   when a timer set to a predetermined time expires without        receiving the repetitive broadcast message, remove the third        entry from the configuration list.

Embodiment #14. A battery system configured for electrically powering anend device and comprising a plurality of battery packs, the batterysystem comprising:

-   -   a first battery pack including:        -   a first communication interface circuit configured to            interface to a controller area network (CAN) bus;        -   a first controller comprising at least one processor; and        -   a first memory storing controller instructions that, when            executed by the at least one processor, cause the first            controller to:        -   obtain a configuration list of installed battery packs in            the battery system, wherein a first entry corresponds to the            first battery pack;        -   when the first entry of the configuration list has a top            priority position in the configuration list, configure first            battery pack to serve as a master battery pack of the            battery system, wherein the top priority position is            indicative that the first battery pack was installed before            any other active battery packs in the battery system;        -   when the first battery pack serves as the master battery            pack, revise the configuration list when a third battery            pack is installed or removed from the battery system; and        -   repetitively broadcast the configuration list to all            installed battery packs over the CAN bus via the first            communication interface circuit; and    -   a second battery pack, wherein the second battery pack has        electrical and electronics components identical to the first        battery pack.

Embodiment #15. The battery system of Embodiment #14, wherein the secondbattery pack comprises:

-   -   a second communication interface circuit configured to interface        to the controller area network (CAN) bus;    -   a second controller comprising one or more processors; and    -   a second memory storing controller instructions that, when        executed by the one or more processors, cause the second        controller to:        -   obtain the configuration list of the installed battery packs            in the battery system, wherein a second entry corresponds to            the second battery pack;        -   when the second entry of the configuration list has the top            priority position in the configuration list, configure the            second battery pack to serve as the master battery pack of            the battery system, wherein the top priority position is            indicative that the second battery pack was installed before            said any other active battery packs in the battery system;        -   revise the configuration list when the third battery pack is            installed or removed from the battery system; and        -   repetitively broadcast the configuration list to all said            installed battery packs over the CAN bus via the second            communication interface circuit.

Embodiment #16. The battery system of Embodiment #15, wherein the firstcontroller instructions, when executed by the one or more processors,further cause the first controller to:

-   -   when the second battery pack previously served as the master        battery pack when the first entry is in a second position from        the top priority position in the configuration list, configure        the first battery pack to serve as the master battery pack.

Embodiment #17. A method of powering an end device by a battery system,the method comprising:

-   -   obtaining a configuration list of installed battery packs in the        battery system, wherein a first entry corresponds to a first        battery pack;    -   when the first entry of the configuration list has a top        priority position in the configuration list, configuring the        first battery pack to serve as a master battery pack of the        battery system, wherein the top priority position is indicative        that the first battery pack was installed before any other        active battery packs in the battery system;    -   revising the configuration list when a second battery pack is        installed or removed from the battery system; and    -   repetitively broadcasting the configuration list to all        installed battery packs over a communication channel via a        communication interface circuit.

Embodiment #18. The method of Embodiment #17 further comprising:

-   -   when a third battery pack is added to the battery system,        detecting an insertion of the third battery pack;    -   creating a third entry for the third battery pack in the        configuration list, wherein the third entry is at a bottom        position of the configuration list; and    -   in response to the creating, broadcasting the configuration list        to said all installed battery packs configured in the battery        system via the communication channel.

Embodiment #19. The method of Embodiment #18 further comprising:

-   -   when the second battery pack is removed from the battery system,        detecting removal of the second battery pack; and    -   deleting a second entry for the second battery pack in the        configuration list.

Embodiment #20. The method of Embodiment #17 further comprising:

-   -   when the first entry for the first battery pack is not at the        top priority position in the configuration list, configure the        first battery pack to serve as a slave battery pack.

Embodiment #21. The method of Embodiment #20 further comprising:

-   -   when another battery pack is removed from the battery system and        the first entry moves to the top priority position of the        configuration list, configuring the first battery pack to serve        as the master battery pack.

Embodiment #22. A battery system configured for electrically powering anend device and comprising a plurality of battery packs, the batterysystem comprising:

-   -   a power bus coupled to the end device to provide electrical        power to the end device;    -   a communication channel coupled to the plurality of battery        packs;    -   a first battery pack including:        -   a first communication interface circuit configured to            interface to the communication channel;        -   a first discharging array;        -   a first processor; and        -   a first memory storing computer-executable instructions            that, when executed by the first processor, cause the first            battery pack to:        -   disable the first discharging array to prevent discharging            onto the power bus from the first battery pack;        -   obtain a first open circuit voltage measurement of the first            battery pack; and        -   share the first open circuit voltage measurement with the            plurality of battery packs via the communication channel;        -   maintain a first copy of a configuration list based on the            first open circuit voltage measurement and shared open            circuit voltage measurements from the plurality of battery            packs; and        -   enable the first discharging array to allow discharging onto            the power bus; and a second battery pack including:        -   a second communication interface circuit configured to            interface to the communication channel;        -   a second discharging array electrically connected to the            power bus of the battery system;        -   a second processor; and        -   a second memory storing computer-executable instructions            that, when executed by the second processor, cause the            second battery pack to:        -   disable the second discharging array to prevent discharging            onto the power bus from the second battery pack;        -   obtain a second open circuit voltage measurement of the            second battery pack; and        -   share the second open circuit voltage measurement with the            plurality of battery packs via the communication channel;        -   maintain a second copy of the configuration list based the            second open circuit voltage measurement and the shared open            circuit voltage measurements from the plurality of battery            packs, wherein the configuration list is ordered based on            decreasing open circuit voltage measurements and wherein the            a top member of the configuration list is designated as a            master battery pack of the battery system; and        -   enable the second discharging array to allow discharging            onto the power bus.

Embodiment #23. The battery system of Embodiment #22 comprising:

-   -   a third battery pack, wherein the third battery pack is        installed in the battery system when the first and second        battery packs are discharging onto the power bus, the third        battery pack including:        -   a third communication interface circuit configured to            interface to the communication channel;        -   a third discharging array;        -   a third processor; and        -   a third memory storing computer-executable instructions            that, when executed by the third processor, cause the third            battery pack to:        -   disable the third discharging array to prevent discharging            onto the power bus from the third battery pack;        -   obtain a third open circuit voltage measurement of the third            battery pack; and        -   share the third open circuit voltage measurement with the            plurality of battery packs via the communication channel.

Embodiment #24. The battery system of Embodiment #23, wherein the thirdmemory storing computer-executable instructions that, when executed bythe third processor, cause the third battery pack to:

-   -   update a third copy of the configuration list based the third        open circuit voltage measurement and the shared open circuit        voltage measurements from the plurality of battery packs.

Embodiment #25. The battery system of Embodiment #24, wherein theupdating occurs after the first and second battery packs aredisconnected from the battery system.

Embodiment #26. The battery system of Embodiment #24, wherein theupdating occurs while the first and second battery packs are dischargingonto the power bus.

Embodiment #27. A method of powering an end device by a battery system,the battery system comprising a plurality of previously installedbattery packs, wherein the plurality of previously installed batterypacks include a master battery pack, the method comprising:

-   -   inserting an additional battery pack into the battery system        establishing a first connection to a power bus and a second        connection to a communication bus;    -   interacting, by the additional battery pack, with the master        battery pack; and    -   in response to the interacting, preventing an in-rush current        from the additional battery pack to one of the plurality of        previously installed battery packs.

Embodiment #28. The method of Embodiment #27, wherein the preventingcomprises:

-   -   receiving, by the additional battery pack from the master        battery pack, a first disable message via the communication bus,        wherein the first disable message instructs the additional        battery pack to disable charging and discharging through the        power bus.

Embodiment #29. The method of Embodiment #27, further comprising:

-   -   in response to the inserting, providing an insertion indication        by the additional battery pack via the communication bus,        wherein the insertion indication includes an identification (ID)        of the additional battery pack.

Embodiment #30. The method of Embodiment #29, further comprising:

-   -   in response to the providing, receiving a configuration message,        wherein the configuration message includes a configuration list        indicative of a battery system configuration, wherein an entry        in the configuration list for the additional battery pack is        located at a bottom position of the configuration list, and        wherein the additional battery pack serves as a slave battery        pack in the battery system.

Embodiment #31. The method of Embodiment #30, further comprising:

-   -   obtaining, by the additional battery pack, first battery status        information about battery cells located at the additional        battery pack, wherein the first battery status information        includes a first state of charge (SoC) value for the battery        cells;    -   receiving, by the additional battery pack from the master        battery pack over the communication bus, a first status request        for the first battery status information; and    -   in response to the receiving the first status request, sending        the first SoC value to the master battery pack over the        communication bus.

Embodiment #32. The method of Embodiment #31, further comprising:

-   -   receiving, from the additional battery pack, the first SoC        value;    -   determining, by the master battery pack, whether to initiate        charge balancing that includes the additional battery pack based        on the first SoC value; and    -   in response to the determining, sending, by the master battery        pack to the additional battery pack an enable message to        configure the additional battery pack with the power bus.

Embodiment #33. The method of Embodiment #32, further comprising:

-   -   receiving, by the additional battery pack from the master        battery pack, the enable message via the communication bus; and    -   configuring the additional battery pack to interact with the        power bus in accordance with the enable message.

Embodiment #34. The method of Embodiment #32, wherein the determiningwhether to initiate charge balancing comprises:

-   -   when the first SoC value is a high SoC value relative to the        plurality of previously installed battery packs, sending, by the        master battery pack, the enable message instructing the        additional battery pack to enable discharging of the battery        cells onto the power bus; and    -   when the first SoC value is a low SoC value relative to the        plurality of previously installed battery packs, sending, by the        master battery pack, the enable message instructing the        additional battery pack to enable charging of the battery cells        from the power bus.

Embodiment #35. The method of Embodiment #34, wherein the determiningwhether to initiate charge balancing further comprises:

-   -   when the first SoC value equals the low SoC value and a        difference between the high SoC value and the low SoC value is        greater than a predetermined amount, sending the enable message        instructing the additional battery pack to enable the charging        of the battery cells from the power bus through a converter        located at the additional battery pack.

Embodiment #36. The method of Embodiment #34, further comprising;

-   -   after receiving the enable message by the additional battery        pack from the master battery pack, obtaining a second SoC value        of the battery cells;    -   receiving, by the additional battery pack from the master        battery pack over the communication bus, a second status request        for second battery status information; and    -   in response to the receiving the second status request, sending        the second SoC value to the master battery pack over the        communication bus.

Embodiment #37. The method of Embodiment #36, further comprising:

-   -   receiving, from the additional battery pack, the second SoC        value;    -   when the first SoC value equals the high SoC value and the        second SoC value is below a first threshold, sending, by the        master battery pack, a second disable message instructing the        additional battery pack to terminate discharging of the battery        cells onto the power bus; and    -   when the first SoC value equals the low SoC value and the second        SoC value is greater than a second threshold, sending, by the        master battery pack, the second disable message instructing the        additional battery pack to terminate charging of the battery        cells from the power bus.

Embodiment #38. The method of Embodiment #27, wherein the communicationbus comprises a controller area network (CAN) bus.

Embodiment #39. A first battery pack configured for installation in abattery system for electrically powering an end device, wherein allinstalled battery packs installed in the battery system have identicalelectrical and electronic components, the first battery pack comprising:

-   -   a communication interface circuit configured to interface to a        communication channel;    -   a power bus interface circuit configured to interface with a        power bus and to provide electrical power to the end device;    -   a controller comprising at least one processor; and    -   a memory storing controller instructions that, when executed by        the at least one processor, cause the controller to:    -   when the first battery pack is inserted into the battery system,        generate an insertion indication via the communication channel,        wherein the insertion indication includes an identification (ID)        of the first battery pack.    -   in response to the generating the insertion indication, receive        from a master battery pack of the battery system, a disable        message over the communication channel via the communication        interface circuit; and    -   in response to the receiving the disable message, disable        charging and discharging through the power bus.

Embodiment #40. The first battery pack of Embodiment #39, wherein thecontroller instructions, when executed by the at least one processor,further cause the controller to:

-   -   in response to the generating the insertion indication, receive        a configuration message, wherein the configuration message        includes a configuration list indicative of a battery system        configuration, wherein an entry in the configuration list for        the first battery pack is located at a bottom position of the        configuration list, and wherein the first battery pack serves as        a slave battery pack in the battery system.

Embodiment #41. The first battery pack of Embodiment #40, wherein thecontroller instructions, when executed by the at least one processor,further cause the controller to:

-   -   obtain battery status information about battery cells located at        the first battery pack, wherein the battery status information        includes a state of charge (SoC) value for the battery cells;    -   receive, from the master battery pack over the communication        channel, a status request for the battery status information;        and    -   in response to the receiving the status request, send the SoC        value to the master battery pack over the communication channel.

Embodiment #42. The first battery pack of Embodiment #41, wherein thecontroller instructions, when executed by the at least one processor,further cause the controller to:

-   -   in response to the sending the SoC value, receive, from the        master battery pack, an enable message via the communication        channel; and    -   configure the power bus interface circuit to interact with the        power bus in accordance with the enable message.

Embodiment #43. A battery system configured for electrically powering anend device and comprising a plurality of battery packs, the batterysystem comprising:

-   -   a first battery pack including:        -   a power bus interface circuit configured to interface with a            power bus and to provide electrical power to the end device;        -   a first communication interface circuit configured to            interface to a controller area network (CAN) bus;        -   a first controller comprising at least one processor; and        -   a first memory storing controller instructions that, when            executed by the at least one processor, cause the first            controller to:            -   when the first battery pack is inserted into the battery                system, provide an insertion indication via the CAN bus,                wherein the insertion indication includes an                identification (ID) of the first battery pack;            -   in response to the providing, receive from a master                battery pack of the battery system a first disable                message over the CAN bus via the first communication                interface circuit; and            -   in response to the receiving, disable charging and                discharging through the power bus; and    -   a second battery pack serving as the master battery pack of the        battery system.

Embodiment #44. The battery system of Embodiment #43, wherein the firstmemory storing controller instructions that, when executed by the atleast one processor, cause the first controller to:

-   -   obtain battery status information about battery cells located at        the first battery pack, wherein the battery status information        includes a state of charge (SoC) value for the battery cells;    -   receive, from the master battery pack over the CAN bus, a status        request for the battery status information; and    -   in response to the receiving the status request, send the SoC        value to the master battery pack over the CAN bus.

Embodiment #45. The battery system of Embodiment #44, wherein the secondbattery pack includes:

-   -   a second communication interface circuit configured to interface        to the CAN bus;    -   a second controller comprising one or more processors; and    -   a second memory storing controller instructions that, when        executed by the one or more processors, cause the second        controller to:        -   receive, from the first battery pack, the SoC value;        -   determine, by the master battery pack, whether to initiate            charge balancing that includes the first battery pack based            on the SoC value; and        -   in response to the determining whether to initiate charge            balancing, send, by the master battery to the first battery            pack an enable message to configure the first battery pack            with the power bus.

Embodiment #46. The battery system of Embodiment #45, wherein the secondmemory storing controller instructions that, when executed by the one ormore processors, further cause the second controller to:

-   -   when the SoC value is a high SoC value relative to a plurality        of previously installed battery packs, send, by the master        battery pack, the enable message instructing the first battery        pack to enable discharging of the battery cells onto the power        bus; and        when the SoC value is a low SoC value relative to the plurality        of previously installed battery packs, send, by the master        battery pack, the enable message instructing the first battery        pack to enable charging of the battery cells from the power bus.

Embodiment #47. A first battery pack configured for installation in abattery system for electrically powering an end device, wherein allinstalled battery packs installed in the battery system have identicalelectrical and electronic components, the first battery pack comprising:

-   -   one or more battery cells;    -   a communication interface circuit configured to interface to a        communication channel;    -   a power bus interface circuit configured to interface with a        power bus and to provide electrical power to the end device;    -   a controller comprising at least one processor; and    -   a memory storing controller instructions that, when executed by        the at least one processor, cause the controller to:        -   determining that the first battery pack is a master battery            pack of the battery system;        -   when the first battery pack receives a first failure            notification message from a second battery pack over the            communication channel via the communication interface            circuit and when an extra battery pack is needed, determine            whether a first spare battery pack is available, wherein the            first failure notification message is indicative of a first            catastrophic failure at the second battery pack;        -   when the first spare battery pack is an only spare battery            pack and when the extra battery pack is needed, send a first            enable message to the first spare battery pack over the            communication channel, wherein the first enable message            instructs the first spare battery pack to discharge onto the            power bus; and        -   when the first battery pack receives the first failure            notification message from the second battery pack, send a            first disable message to the second battery pack over the            communication channel, wherein the first disable message            instructs the second battery pack to terminate discharging            onto the power bus.

Embodiment #48. The first battery pack of Embodiment #47, wherein thecontroller instructions, when executed by the at least one processor,further cause the controller to:

-   -   when the first battery pack is the master battery pack of the        battery system:        -   when no spare battery packs are available, send a            degradation alert message to the end device.

Embodiment #49. The first battery pack of Embodiment #48, wherein thecontroller instructions, when executed by the at least one processor,further cause the controller to:

-   -   when the first battery pack is the master battery pack of the        battery system:        -   when degraded operation is not acceptable to the end device,            initiate shutdown of the battery system.

Embodiment #50. The first battery pack of Embodiment #49, wherein thecontroller instructions, when executed by the at least one processor,further cause the controller to:

-   -   when the first battery pack is the master battery pack of the        battery system:        -   instructing all battery packs of the battery system from            discharging onto the power bus.

Embodiment #51. The first battery pack of Embodiment #47, wherein thecontroller instructions, when executed by the at least one processor,further cause the controller to:

-   -   when the first battery pack is the master battery pack of the        battery system:        -   when a plurality of spare battery packs are available,            select a highest SoC spare battery pack from the plurality            of spare battery packs, wherein the highest SoC spare            battery pack is characterized by a highest state of charge            (SoC) value of all of the plurality of spare battery packs;            and        -   send a second enable message to the highest SoC spare            battery pack, wherein the second enable message instructs            the highest SoC spare battery pack to discharge onto the            power bus.

Embodiment #52. The first battery pack of Embodiment #47, wherein thecommunication channel comprises a controller area network (CAN) bus.

Embodiment #53. The first battery pack of Embodiment #47, wherein thecontroller instructions, when executed by the at least one processor,further cause the controller to:

-   -   when the first battery pack is the master battery pack of the        battery system:        -   monitor the one or more battery cells;        -   based on the monitoring, determine whether a second            catastrophic failure has occurred;        -   when the second catastrophic failure has occurred, determine            whether the first spare battery pack is available;        -   when the first battery pack is available, send the first            enable message to the first spare battery pack, wherein the            first enable message instructs the first spare battery pack            to discharge onto the power bus; and        -   disable itself from discharging onto the power bus.

Embodiment #54. The first battery pack of Embodiment #47, wherein thecontroller instructions, when executed by the at least one processor,further cause the controller to:

-   -   when the first battery pack is a slave battery pack of the        battery system:        -   monitor the one or more battery cells;        -   based on the monitoring, determine whether a third            catastrophic failure has occurred; and        -   when the third catastrophic failure has occurred, send a            second failure notification message to the master battery            pack of the battery system.

Embodiment #55. The first battery pack of Embodiment #54, wherein thecontroller instructions, when executed by the at least one processor,further cause the controller to:

-   -   in response to the sending, receive a second disable message        from the master battery pack; and    -   in response to the receiving, terminate discharging onto the        power bus.

Embodiment #56. The first battery pack of Embodiment #47, wherein thecontroller instructions, when executed by the at least one processor,further cause the controller to:

-   -   when the first battery pack detects an internal catastrophic        failure, internally terminate discharging onto the power bus;    -   when at least one spare battery pack is available, enable one of        the at least one spare battery packs;    -   when no spare battery packs is available, send a degradation        alert message to the end device; and    -   continue to operate as the master battery pack of the battery        system.

Embodiment #57. The first battery pack of Embodiment #47, wherein thecontroller instructions, when executed by the at least one processor,further cause the controller to:

-   -   when the first battery pack detects an internal catastrophic        failure, internally terminate discharging onto the power bus;        and    -   reassign one of the slave battery packs as a new master battery        pack.

Embodiment #58. The first battery pack of Embodiment #47, wherein thecontroller instructions, when executed by the at least one processor,further cause the controller to:

-   -   when the first battery pack fails to receive any messages from        the second battery pack over the communications channel, attempt        to disable the second battery pack from discharging onto the        power bus; and    -   adjust a power level over the power bus to the end device.

Embodiment #59. A method of powering an end device by a battery system,the method comprising:

-   -   when a master battery pack receives a failure notification        message from a slave battery pack over a communication channel        and when an extra battery pack is needed, determining whether a        first spare battery pack is available, wherein the failure        notification message is indicative of a catastrophic failure at        the slave battery pack;    -   when the first spare battery pack is an only spare battery pack        and when the extra battery pack is needed, sending, by the        master battery pack, an enable message to the first spare        battery pack, wherein the enable message instructs the first        spare battery pack to discharge onto a power bus; and    -   when the master battery pack receives the failure notification        message from the slave battery pack, sending, by the master        battery pack, a disable message to the slave battery pack,        wherein the disable message instructs the slave battery pack to        terminate discharging onto the power bus.

Embodiment #60. The method of Embodiment #59, comprising:

-   -   when degraded operation is not acceptable to the end device,        initiating shutdown of the battery system.

Embodiment #61. The method of Embodiment #59, comprising:

-   -   when a plurality of spare battery packs are available, selecting        a highest SoC spare battery pack from the plurality of spare        battery packs, wherein the highest SoC spare battery pack is        characterized by a highest state of charge (SoC) value of all of        the plurality of spare battery packs; and    -   sending the enable message to the highest SoC spare battery        pack, wherein the enable message instructs the highest SoC spare        battery pack to discharge onto the power bus.

Embodiment #62. The method of Embodiment #59, comprising:

-   -   monitoring, by the slave battery pack, one or more battery        cells;    -   based on the monitoring, determining whether the catastrophic        failure has occurred; and    -   when the catastrophic failure has occurred, sending the failure        notification message to the master battery pack of the battery        system.

Embodiment #63. The method of Embodiment #62, comprising:

-   -   in response to the sending, receiving, by the slave battery        pack, the disable message from the master battery pack; and    -   in response to the receiving the disable message, terminating        discharging onto the power bus.

Embodiment #64. A battery system configured for electrically powering anend device and comprising a plurality of battery packs, the batterysystem comprising:

-   -   a slave battery pack; and    -   a master battery pack including:        -   a first communication interface circuit configured to            interface to a controller area network (CAN) bus;        -   a first controller comprising at least one processor; and        -   a first memory storing controller instructions that, when            executed by the at least one processor, cause the first            controller to:            -   when the master battery pack receives a failure                notification message from the slave battery pack over                the CAN bus via the first communication interface                circuit and when an extra battery pack is needed,                determine whether a first spare battery pack is                available, wherein the failure notification message is                indicative of a catastrophic failure at the slave                battery pack;            -   when the first spare battery pack is an only spare                battery pack and when the extra battery pack is needed,                send an enable message to the first spare battery pack,                wherein the enable message instructs the first spare                battery pack to discharge onto a power bus; and            -   when the master battery pack receives the failure                notification message from the slave battery pack, send a                disable message to the slave battery pack, wherein the                disable message instructs the slave battery pack to                terminate discharging onto the power bus.

Embodiment #65. The battery system of Embodiment #64, wherein the firstmemory storing controller instructions that, when executed by the atleast one processor, cause the first controller to:

-   -   when degraded operation is not acceptable to the end device,        initiate shutdown of the battery system.

Embodiment #66. The battery system of Embodiment #65, wherein the firstmemory storing controller instructions that, when executed by the atleast one processor, cause the first controller to:

-   -   instruct all battery packs of the battery system from        discharging onto the power bus.

Embodiment #67. The battery system of Embodiment #64, wherein the firstmemory storing controller instructions that, when executed by the atleast one processor, cause the first controller to:

-   -   when a plurality of spare battery packs is available, select a        highest SoC spare battery pack from the plurality of spare        battery packs, wherein the highest SoC spare battery pack is        characterized by a highest state of charge (SoC) value of all of        the plurality of spare battery packs; and    -   send the enable message to the highest SoC spare battery pack,        wherein the enable message instructs the highest SoC spare        battery pack to discharge onto the power bus.

Embodiment #68. The battery system of Embodiment #64, wherein the slavebattery pack includes:

-   -   a second communication interface circuit configured to interface        to a controller area network (CAN) bus;    -   a second controller comprising one or more processors;    -   one or more battery cells; and    -   a second memory storing controller instructions that, when        executed by the one or more processors, cause the first        controller to:        -   monitor the one or more battery cells;        -   based on the monitoring, determine whether the catastrophic            failure has occurred; and        -   when the catastrophic failure has occurred, send the failure            notification message to the master battery pack of the            battery system.

Embodiment #69. The battery system of Embodiment #68, wherein the secondmemory storing controller instructions that, when executed by the one ormore processors, cause the second controller to

-   -   in response to the sending the failure notification message,        receive the disable message from the master battery pack; and    -   in response to the receiving the disable message, terminate        discharging onto the power bus.

Embodiment #70. A method of powering an end device by a battery system,the battery system comprising a plurality of battery packs, the methodcomprising:

-   -   gathering, by a master battery pack of the battery system,        battery status information from the plurality of battery packs,        wherein the plurality of battery pack comprises the master        battery packs and all slave battery packs and wherein the        battery status information includes a state of charge (SoC)        data;    -   determining, by the master battery pack and based the battery        status information, whether a first subset of the plurality of        battery packs needs to be balanced in charge;    -   selecting, by the master battery pack, a first type of balancing        from a plurality of balancing types appropriate for the first        subset of the plurality of battery packs; and    -   applying, by the master battery pack, the selected first type of        balancing via a power bus until desired SoC values are obtained        for the first subset of the plurality of battery packs.

Embodiment #71. The method of Embodiment #70, wherein the plurality ofbalancing types comprise a converter balancing technique, a directbalancing technique, and a staggered balancing technique.

Embodiment #72. The method of Embodiment #71, comprising:

-   -   identifying, by the master battery pack, a first battery pack        having a high SoC value from the gathered battery status        information; and    -   comparing, by the master battery pack, the high SoC value with        SoC values of all remaining battery packs.

Embodiment #73. The method of Embodiment #72, comprising:

-   -   in response to the comparing, when a first SoC difference        between the first battery pack and a second battery pack is        greater than a first predetermined amount, initiating, by the        master battery pack, the converter balancing technique for the        first and second battery packs.

Embodiment #74. The method of Embodiment #73, comprising:

-   -   sending, by the master battery pack, to the first battery pack a        first enable message over a communication channel, wherein the        first enable message instructs the first battery pack to        discharge over the power bus; and    -   sending, by the master battery pack, to the second battery pack        a second enable message over the communication channel, wherein        the second enable message instructs the second battery pack to        enable its converter and to charge from the power bus.

Embodiment #75. The method of Embodiment #73, comprising:

-   -   in response to the comparing, when a second SoC difference        between the first battery pack and a third battery pack is        greater than the first predetermined amount, initiating, by the        master battery pack, the converter balancing technique for the        first, second, and third battery packs.

Embodiment #76. The method of Embodiment #75, wherein one of the first,second, and third battery packs serves as the master battery pack of thebattery system.

Embodiment #77. The method of Embodiment #72, comprising:

-   -   in response to the comparing, when a third SoC difference        between the first battery pack and a fourth battery pack is less        than a second predetermined amount, initiating, by the master        battery pack, the direct balancing technique for the first        battery pack and the fourth battery pack.

Embodiment #78. The method of Embodiment #77, comprising:

-   -   sending, by the master battery pack, to the first battery pack a        third enable message over a communication channel, wherein the        third enable message instructs the first battery pack to        discharge over the power bus; and    -   sending, by the master battery pack, to the fourth battery pack        a fourth enable message over the communication channel, wherein        the fourth enable message instructs the fourth battery pack to        charge from the power bus.

Embodiment #79. The method of Embodiment #77, wherein one of the firstand fourth battery packs serves as the master battery pack.

Embodiment #80. The method of Embodiment #72, comprising:

-   -   in response to the comparing, when a fourth SoC difference        between the first battery pack and a fifth battery pack is less        than a third predetermined amount, a fifth SoC difference        between the first battery pack and a sixth battery pack is        greater than a fourth predetermined amount, and a sixth SoC        difference between the first battery pack and a seventh battery        pack is greater than the fourth predetermined amount, initiating        the staggered balancing technique to the first battery pack, the        fifth battery pack, and the sixth battery pack.

Embodiment #81. The method of Embodiment #80, comprising:

-   -   sending, by the master battery pack, to the first battery pack a        fifth enable message over a communication channel, wherein the        fifth enable message instructs the first battery pack to        discharge over the power bus;    -   sending, by the master battery pack, to the fifth battery pack a        sixth enable message over the communication channel, wherein the        sixth enable message instructs the fifth battery pack to charge        from the power bus, wherein the direct balancing technique is        applied for the first battery pack and the fifth battery pack;        and    -   sending, by the master battery pack, to the sixth battery pack a        seventh enable message over the communication channel, wherein        the seventh enable message instructs the sixth battery pack to        enable its converter and to charge from the power bus, wherein        the converter balancing technique is applied for the first        battery pack and the sixth battery pack.

Embodiment #82. The method of Embodiment #81, comprising:

-   -   obtaining current SoC values for the fifth and sixth battery        packs; and    -   in response to the obtaining, when an eighth difference between        a first current SoC value of the fifth battery pack and a second        current SoC value of the sixth battery pack is greater than a        fifth predetermined value, switching the direct balancing        technique to the first battery pack and the seventh battery pack        from the first battery pack and the sixth battery pack.

Embodiment #83. The method of Embodiment #82, comprising:

-   -   sending, by the master battery pack, to the fifth battery pack        an eighth enable message over the communication channel, wherein        the eighth enable message instructs the fifth battery pack to        enable its converter and charge from the power bus, wherein the        converter balancing technique is applied for the first battery        pack and the fifth battery pack; and    -   sending, by the master battery pack, to the sixth battery pack a        ninth enable message over the communication channel, wherein the        ninth enable message instructs the sixth battery pack to disable        its converter and to charge from the power bus, wherein the        direct balancing technique is applied for the first battery pack        and the sixth battery pack.

Embodiment #84. The method of Embodiment #75, wherein one of the first,fifth, and sixth battery packs serves as the master battery pack of thebattery system.

Embodiment #85. The method Embodiment #70, further comprising:

-   -   obtaining, by the master battery pack, current SoC values from        the plurality of battery packs;    -   determining, by the master battery pack and based the current        SoC values, whether a second subset of the plurality of battery        packs needs to be balanced in charge;    -   selecting, by the master battery pack, a second type of        balancing from the plurality of balancing types appropriate for        the second subset of the plurality of battery packs, wherein the        first type and second type of balancing are different; and    -   applying, by the master battery pack, the selected second type        of balancing for the second subset of the plurality of battery        packs.

Embodiment #86. The method Embodiment #70, wherein the applyingcomprises:

-   -   obtaining a safety interlock indicator and a wake indicator; and    -   only when the safety interlock indicator is indicative of being        on and the wake indicator is indicative of being off, enabling        the applying.

Embodiment #87. A first battery pack configured for installation in abattery system for electrically powering an end device, wherein allinstalled battery packs installed in the battery system have identicalelectrical and electronic components, the first battery pack comprising:

-   -   a communication interface circuit configured to interface to a        communication channel;    -   a power bus interface circuit configured to interface with a        power bus and to provide electrical power to the end device;    -   a controller comprising at least one processor; and    -   a memory storing controller instructions that, when executed by        the at least one processor, cause the controller to:    -   when the first battery pack serves as a master battery pack of        the battery system:        -   gather battery status information from a plurality of            battery packs, wherein the plurality of battery pack            comprises the master battery packs and all slave battery            packs and wherein the battery status information includes a            state of charge (SoC) data;        -   determine, based the battery status information, whether a            first subset of the plurality of battery packs needs to be            balanced in charge;        -   select a first type of balancing from a plurality of            balancing types appropriate for the first subset of the            plurality of battery packs; and        -   apply the selected first type of balancing until desired SoC            values are obtained for the first subset of the plurality of            battery packs.

Embodiment #88. The first battery pack of Embodiment #87, wherein thememory storing controller instructions that, when executed by the atleast one processor, cause the controller to:

-   -   identify a first battery pack having a high SoC value from the        gathered battery status information; and    -   compare the high SoC value with SoC values of all remaining        battery packs.

Embodiment #89. The first battery pack of Embodiment #88, wherein thememory storing controller instructions that, when executed by the atleast one processor, cause the controller to:

-   -   in response to the comparing, when a first SoC difference        between the first battery pack and a second battery pack is        greater than a first predetermined amount, initiate, by the        master battery pack, a converter balancing technique for the        first and second battery packs.

Embodiment #90. The first battery pack of Embodiment #88, wherein thememory storing controller instructions that, when executed by the atleast one processor, cause the controller to:

-   -   in response to the comparing, when a third SoC difference        between the first battery pack and a fourth battery pack is less        than a second predetermined amount, initiate, by the master        battery pack, a direct balancing technique for the first battery        pack and the fourth battery pack.

Embodiment #91. The first battery pack of Embodiment #88, wherein thememory storing controller instructions that, when executed by the atleast one processor, cause the controller to:

-   -   in response to the comparing, when a fourth SoC difference        between the first battery pack and a fifth battery pack is less        than a third predetermined amount, a fifth SoC difference        between the first battery pack and a sixth battery pack is        greater than a fourth predetermined amount, and a sixth SoC        difference between the first battery pack and a seventh battery        pack is greater than the fourth predetermined amount, initiate a        staggered balancing technique to the first battery pack, the        fifth battery pack, and the sixth battery pack.

Embodiment #92. A battery system configured for electrically powering anend device and comprising a plurality of battery packs, the batterysystem comprising:

-   -   a plurality of slave battery packs; and    -   a master battery pack including:        -   a first communication interface circuit configured to            interface to a controller area network (CAN) bus;        -   a controller comprising at least one processor; and        -   a memory storing controller instructions that, when executed            by the at least one processor, cause the controller to:        -   gather battery status information from all battery packs of            the battery system, wherein said all battery packs comprises            the master battery packs and the plurality of slave battery            packs and wherein the battery status information includes a            state of charge (SoC) data;        -   determine, based the battery status information, whether a            first subset of said all battery packs needs to be balanced            in charge;        -   select a first type of balancing from a plurality of            balancing types appropriate for the first subset of said all            battery packs; and        -   apply the selected first type of balancing until desired SoC            values are obtained for the first subset of said all battery            packs.

Embodiment #93. The battery system of Embodiment #92, wherein the memorystoring controller instructions that, when executed by the at least oneprocessor, cause the controller to:

-   -   identify a first battery pack having a high SoC value from the        gathered battery status information, wherein the plurality of;        and    -   compare the high SoC value with SoC values of all remaining        battery packs.

Embodiment #94. The battery system of Embodiment #93, wherein the memorystoring controller instructions that, when executed by the at least oneprocessor, cause the controller to:

-   -   in response to the comparing:    -   when a first SoC difference between the first battery pack and a        second battery pack is greater than a first predetermined        amount, initiate a converter balancing technique for the first        and second battery packs;    -   when the first SoC difference between the first battery pack and        the second battery pack is less than a second predetermined        amount, initiate a direct balancing technique for the first        battery pack and the second battery pack; and    -   when the first SoC difference between the first battery pack and        the second battery pack is less than the second predetermined        amount, a second SoC difference between the first battery pack        and a third battery pack is greater than the first predetermined        amount, and a third SoC difference between the first battery        pack and a fourth battery pack is greater than the first        predetermined amount, initiate a staggered balancing technique        to the first, second, third, and fourth battery packs.

Embodiment #95. A method comprising:

-   -   receiving, by a computing device having one or more processors,        a first reading of a state of charge (SOC) of each of a        plurality of battery packs, wherein the plurality of battery        packs comprises at least a first group of one or more battery        packs and a second group of one or more battery packs;    -   identifying, by the computing device, based on the received        first reading of the SOC of each of the plurality of battery        packs, and based on an identification of a lowest level for a        first reading of an SOC and a second lowest level for a first        reading of an SOC,        -   the first group as having the lowest level for the first            reading of the SOC, and        -   the second group as having the second lowest level for the            first reading of the SOC;    -   generating, by the computing device and based on the        identification of the lowest level and the second lowest level,        a first list comprising of the first group and the second group;    -   determining, by the computing device, based on the first reading        of the SOC of the first group, and based on the first reading of        the SOC of the second group, a first SOC variability of the        first list;    -   determining, by the computing device and based on the first SOC        variability, that the first SOC variability does not satisfy a        SOC variability threshold;    -   establishing, by the computing device, a first SOC threshold        using the first reading of the SOC of the second group;    -   causing, by the computing device and via electric charge arrays,        the charging of the first group to cause the SOC of the first        group to increase;    -   receiving, by the computing device, a second reading of the SOC        of each of the plurality of battery packs;    -   determining, by the computing device and based on a second        reading of the SOC of the first group, that the second reading        of the SOC of the first group satisfies the first SOC threshold.

Embodiment #96. The method of Embodiment #95, further comprising:

-   -   determining, by the computing device and based on the received        second reading of the SOC of each of the plurality of battery        packs, an updated first SOC variability of the first list;    -   determining, by the computing device, that the updated first SOC        variability satisfies the SOC variability threshold.

Embodiment #97. The method of Embodiment #95, wherein the receiving thefirst reading of the SOC of each of the plurality of battery packsfurther comprises:

-   -   identifying, by the computing device, a master battery pack as        one of the plurality of battery packs; and    -   receiving, by the computing device and from the master battery        pack, the first reading of the SOC of each of the plurality of        battery packs.

Embodiment #98. The method of Embodiment #95, wherein the causing thecharging further comprises enabling an electric discharge array from acharger to the one or more battery packs of the first group of one ormore battery packs via a converter.

Embodiment #99. The method of Embodiment #95, wherein the plurality ofbattery packs further comprises at least a third group of one or morebattery packs, and wherein the method further comprises:

-   -   identifying, by the computing device, based on the received        second reading of the SOC of each of the plurality of battery        packs, and based on an identification of a lowest level for a        second reading of an SOC and a second lowest level for a second        reading of an SOC,        -   the first group and the second group as having the lowest            level for the second reading of the SOC, and        -   the third group as having the second lowest level for the            second reading of the SOC;    -   generating, by the computing device and based on the lowest        level for the second reading of the SOC and the second lowest        level for the second reading of the SOC, a second list        comprising the first group, the second group, and the third        group;    -   determining, by the computing device, based on the second        reading of the SOC of the first group, based on the second        reading of the SOC of the second group, and based on the second        reading of the SOC of the third group, a second SOC variability        of the second list.

Embodiment #100. The method of Embodiment #99, wherein the generatingthe second list comprises expanding the first list to include batterypacks having the second lowest level for the second reading of the SOC.

Embodiment #101. The method of Embodiment #99, further comprising:

-   -   determining, by the computing device, that the second SOC        variability does not satisfy the SOC variability threshold;    -   establishing, by the computing device, a second SOC threshold        based on a second reading of the SOC of the third group;    -   causing, by the computing device and via electric charge arrays,        -   the charging of the first group to cause the SOC of the            first group to increase, and        -   the charging of the second group to cause the SOC of the            second group to increase;    -   receiving, by the computing device, a third reading of the SOC        of each of the plurality of battery packs;    -   determining, by the computing device, that a third reading of        the SOC of the first group and a third reading of the SOC of the        second group each satisfy the second SOC threshold.

Embodiment #102. The method of Embodiment #101, further comprising:

-   -   performing one or more iterations of the following until a        determined updated SOC variability of the plurality of battery        packs satisfies the SOC variability threshold:        -   identifying, by the computing device,            -   an Nth group of one or more battery packs of the                plurality of battery back devices, wherein the nth group                has a lowest level of a previous reading of the SOC of                the plurality of battery packs, and            -   an (N+1) group of one or more battery packs of the                plurality of battery back devices, wherein the (N+1)                group has the second lowest level of the previous                reading of the SOC of the plurality of battery packs,                and        -   generating, by the computing device, a list comprising the n            group and the N+1 group;        -   determining, by the computing device, that an SOC            variability of the list does not satisfy the SOC variability            threshold;        -   establishing, by the computing device, an SOC threshold            using the previous reading of the SOC of the N+1 group;        -   causing, by the computing device and via electric charge            arrays, the charging of the n group to cause the SOC of the            n group to increase and satisfy the SOC threshold;        -   receiving, by the computing device, a subsequent reading of            an SOC of each of the plurality of battery packs; and        -   determining, by the computing device and based on the            subsequent reading of the SOC of each of the plurality of            battery packs, the updated SOC variability of the plurality            of battery packs.

Embodiment #103. The method of Embodiment #95, further comprising:

-   -   prior to the receiving the first reading of the SOC of each of        the plurality of battery packs, determining that an interlock        safety pin associated with the plurality of battery packs is set        to on, wherein the interlock safety pin allows the receiving the        first reading of the SOC of each of the plurality of battery        pack to occur.

Embodiment #104. The method of Embodiment #95, further comprising:

-   -   prior to the causing the charging, determining that a wake pin        associated with the plurality of battery packs is set to on,        wherein the wake pin allows the charging to occur.

Embodiment #105. A method comprising:

-   -   receiving, by a computing device having one or more processors        and communicatively linked to an end device, a power requirement        of the end device;    -   receiving, by the computing device, a first reading of a state        of charge (SOC) of each of a plurality of battery packs,        -   wherein the plurality of battery packs comprises at least a            first group of one or more battery packs and a second group            of one or more battery packs, and        -   wherein a first reading of an SOC of the second group is            greater than a first reading of an SOC of the first group;    -   determining, by the computing device and based on the received        first reading of the SOC of each of the plurality of battery        packs, a first SOC variability of the plurality of battery        packs;    -   determining, by the computing device and based on the first SOC        variability not satisfying an SOC variability threshold, to        enable the second group to initially power the end device        without a concurrent powering of the end device by other battery        packs of the plurality of battery packs; and    -   causing, by the computing device and via an electric charge        array, the second group to power the end device to a first power        level, wherein the powering the end device causes the SOC of the        second group to decrease.

Embodiment #106. The method of Embodiment #105, further comprising:

-   -   receiving, by the computing device, a second reading of an SOC        of each of the plurality of battery packs; and    -   determining, by the computing device and based on the received        second reading of the SOC of each of the plurality of battery        packs, a second SOC variability of the plurality of battery        packs;    -   determining, by the computing device, that the second SOC        variability satisfies the SOC variability threshold; and    -   causing, by the computing device and via one or more electric        charge arrays, the first group and the second group to power the        end device to a second power level, wherein the powering the end        device causes the second reading of the SOC of the first group        and the second reading of the SOC of the second group to        decrease.

Embodiment #107. The method of Embodiment #105, further comprising:

-   -   receiving, by the computing device, a second reading of the SOC        of each of the plurality of battery packs,        -   wherein the plurality of battery packs further comprises a            third group of one or more battery packs,        -   wherein the second reading of the SOC of the second group            and the second reading of the SOC of the third group are            within a predetermined reading of each other, and        -   wherein the second reading of the SOC of the second group            and the second reading of the SOC of the third group are            each greater than the second reading of the SOC of the first            group,    -   determining, by the computing device and based on the received        second reading of the SOC of each of the plurality of battery        packs, a second SOC variability of the plurality of battery        packs;    -   determining, by the computing device, that the second SOC        variability does not satisfy the SOC variability threshold; and    -   causing, by the computing device and via one or more electric        charge arrays, the second group and the third group to        concurrently power the end device to a second power level,        wherein the powering the end device causes the SOC of the second        group and the SOC of the third group to decrease.

Embodiment #108. The method of Embodiment #105, wherein the receivingthe first reading of the SOC of each of the plurality of battery packsfurther comprises:

-   -   identifying, by the computing device, a master battery pack as        one of the plurality of battery packs; and    -   receiving, by the computing device and from the master battery        pack, the first reading of the SOC of each of the plurality of        battery packs.

Embodiment #109. A method comprising:

-   -   receiving, by a computing device having one or more processors        and communicatively linked to an end device, a power requirement        of the end device;    -   receiving, by the computing device, a first reading of a state        of charge (SOC) of each of a plurality of battery packs,        -   wherein the plurality of battery packs comprises at least a            first group of one or more battery packs and a second group            of one or more battery packs,        -   wherein a first reading of an SOC of the second group is            greater than a first reading of an SOC of the first group,            and    -   determining, by the computing device and based on the received        first reading of the SOC of each of the plurality of battery        packs, a first SOC variability of the plurality of battery        packs;    -   determining, by the computing device, that the first SOC        variability does not satisfy an SOC variability threshold; and    -   causing, by the computing device, and via one or more electric        charge arrays, the second group to charge the first group,        wherein the charging the first group decreases the SOC of the        second group and increases the SOC of the first group.

Embodiment #110. The method of Embodiment #109, further comprising:

-   -   receiving, by the computing device, a second reading of the SOC        of each of the plurality of battery packs;    -   determining, by the computing device and based on the received        second reading of the SOC of each of the plurality of battery        packs, a second SOC variability of the plurality of battery        packs; and    -   determining, by the computing device, that the second SOC        variability satisfies the SOC variability threshold.

Embodiment #111. The method of Embodiment #110, further comprising:

-   -   causing, by the computing device and via one or more electric        charge arrays, the plurality of battery packs to power the end        device, wherein the powering causes the SOC of the plurality of        battery packs to decrease.

Embodiment #112. The method of Embodiment #109, further comprising:

-   -   receiving, by the computing device, a first reading of a state        of health (SOH) of each of the plurality of battery packs,        wherein the plurality of battery packs further comprises a third        group of one or more battery packs;    -   determining, by the computing device, that the first reading of        the SOH of the third group does not satisfy a SOH threshold; and    -   sequestering, by the computing device, the third group from        powering the end device until a subsequent reading of an SOC of        each of the plurality of battery packs other than the one or        more battery packs of the third group do not satisfy an SOC        threshold.

Embodiment #113. The method of Embodiment #109, wherein the receivingthe first reading of the SOC of each of the plurality of battery packsfurther comprises:

-   -   identifying, by the computing device, a master battery pack as        one of the plurality of battery packs; and    -   receiving, by the computing device and from the master battery        pack, the first reading of the SOC of each of the plurality of        battery packs.

Embodiment #114. The method of Embodiment #109, wherein the causing thesecond group to charge the first battery pack occurs via one or more ofa converter balancing, a direct connect balancing, or a staggeredbalancing.

With some embodiments, the term “large-format” encompasses medium-formatbattery embodiments and use cases. For example, medium-scale andlarge-scale applications are embodied by the numerous descriptionsherein.

Although many of the systems and methods described herein referenceLithium ion battery storage chemistry, the disclosure is not so limited.In many instances, a person of ordinary skill in the art will appreciatethat other major chemistries for rechargeable batteries may beappropriated substituted without substantially departing from the spiritof the solution: Lithium-ion(Li-ion), Nickel Cadmium(Ni—Cd),Nickel-Metal Hydride(Ni-MH), Lead-Acid, and other chemistries. With someembodiments, the battery management system disclosed herein may beincluded with these technology batteries to provide battery protection,provide improved efficiency, and provide a better user experience thanprevious battery technologies. Variants of the lithium cobalt cathode,such as nickel cobalt aluminum (NCA) and nickel manganese cobalt (NMC),may be desirable in electric vehicles and other applications. Other newcathode chemistries, such as lithium manganese spinel (LMO) and lithiumiron phosphate (LFP), may be used where appropriate. Moreover,large-format battery packs offer lower system integration costs because,inter alia, it enables a reduced number of battery interconnections,further improving the reliability of the battery pack and providing fora much higher value proposition.

As can be appreciated by one skilled in the art, a computer system withan associated computer-readable medium containing instructions forcontrolling the computer system can be utilized to implement theexemplary embodiments that are disclosed herein. The computer system mayinclude at least one computer such as a microprocessor, digital signalprocessor, and associated peripheral electronic circuitry.

We claim:
 1. A method of powering an end device by a battery system, the battery system comprising a plurality of battery packs, the method comprising: gathering, by a master battery pack of the battery system, battery status information from the plurality of battery packs, wherein the plurality of battery pack comprises the master battery packs and all slave battery packs and wherein the battery status information includes a state of charge (SoC) data; determining, by the master battery pack and based on the battery status information, whether a first subset of the plurality of battery packs needs to be balanced in charge; selecting, by the master battery pack, a first type of balancing from a plurality of balancing types appropriate for the first subset of the plurality of battery packs; and applying, by the master battery pack, the selected first type of balancing via a power bus until desired SoC values are obtained for the first subset of the plurality of battery packs.
 2. The method of claim 1, wherein the plurality of balancing types comprise a converter balancing technique, a direct balancing technique, and a staggered balancing technique.
 3. The method of claim 2, comprising: identifying, by the master battery pack, a first battery pack having a high SoC value from the gathered battery status information; and comparing, by the master battery pack, the high SoC value with SoC values of all remaining battery packs.
 4. The method of claim 3, comprising: in response to the comparing, when a first SoC difference between the first battery pack and a second battery pack is greater than a first predetermined amount, initiating, by the master battery pack, the converter balancing technique for the first and second battery packs.
 5. The method of claim 4, comprising: sending, by the master battery pack, to the first battery pack a first enable message over a communication channel, wherein the first enable message instructs the first battery pack to discharge over the power bus; and sending, by the master battery pack, to the second battery pack a second enable message over the communication channel, wherein the second enable message instructs the second battery pack to enable its converter and to charge from the power bus.
 6. The method of claim 4, comprising: in response to the comparing, when a second SoC difference between the first battery pack and a third battery pack is greater than the first predetermined amount, initiating, by the master battery pack, the converter balancing technique for the first, second, and third battery packs.
 7. The method of claim 6, wherein one of the first, second, and third battery packs serves as the master battery pack of the battery system.
 8. The method of claim 3, comprising: in response to the comparing, when a third SoC difference between the first battery pack and a fourth battery pack is less than a second predetermined amount, initiating, by the master battery pack, the direct balancing technique for the first battery pack and the fourth battery pack.
 9. The method of claim 8, comprising: sending, by the master battery pack, to the first battery pack a third enable message over a communication channel, wherein the third enable message instructs the first battery pack to discharge over the power bus; and sending, by the master battery pack, to the fourth battery pack a fourth enable message over the communication channel, wherein the fourth enable message instructs the fourth battery pack to charge from the power bus.
 10. The method of claim 8, wherein one of the first and fourth battery packs serves as the master battery pack.
 11. The method of claim 3, comprising: in response to the comparing, when a fourth SoC difference between the first battery pack and a fifth battery pack is less than a third predetermined amount, a fifth SoC difference between the first battery pack and a sixth battery pack is greater than a fourth predetermined amount, and a sixth SoC difference between the first battery pack and a seventh battery pack is greater than the fourth predetermined amount, initiating the staggered balancing technique to the first battery pack, the fifth battery pack, and the sixth battery pack.
 12. The method of claim 11, comprising: sending, by the master battery pack, to the first battery pack a fifth enable message over a communication channel, wherein the fifth enable message instructs the first battery pack to discharge over the power bus; sending, by the master battery pack, to the fifth battery pack a sixth enable message over the communication channel, wherein the sixth enable message instructs the fifth battery pack to charge from the power bus, wherein the direct balancing technique is applied for the first battery pack and the fifth battery pack; and sending, by the master battery pack, to the sixth battery pack a seventh enable message over the communication channel, wherein the seventh enable message instructs the sixth battery pack to enable its converter and to charge from the power bus, wherein the converter balancing technique is applied for the first battery pack and the sixth battery pack.
 13. The method of claim 12, comprising: obtaining current SoC values for the fifth and sixth battery packs; and in response to the obtaining, when an eighth difference between a first current SoC value of the fifth battery pack and a second current SoC value of the sixth battery pack is greater than a fifth predetermined value, switching the direct balancing technique to the first battery pack and the seventh battery pack from the first battery pack and the sixth battery pack.
 14. The method of claim 13, comprising: sending, by the master battery pack, to the fifth battery pack an eighth enable message over the communication channel, wherein the eighth enable message instructs the fifth battery pack to enable its converter and charge from the power bus, wherein the converter balancing technique is applied for the first battery pack and the fifth battery pack; and sending, by the master battery pack, to the sixth battery pack a ninth enable message over the communication channel, wherein the ninth enable message instructs the sixth battery pack to disable its converter and to charge from the power bus, wherein the direct balancing technique is applied for the first battery pack and the sixth battery pack.
 15. The method of claim 6, wherein one of the first, fifth, and sixth battery packs serves as the master battery pack of the battery system.
 16. The method claim 1, further comprising: obtaining, by the master battery pack, current SoC values from the plurality of battery packs; determining, by the master battery pack and based the current SoC values, whether a second subset of the plurality of battery packs needs to be balanced in charge; selecting, by the master battery pack, a second type of balancing from the plurality of balancing types appropriate for the second subset of the plurality of battery packs, wherein the first type and second type of balancing are different; and applying, by the master battery pack, the selected second type of balancing for the second subset of the plurality of battery packs.
 17. The method claim 1, wherein the applying comprises: obtaining a safety interlock indicator and a wake indicator; and only when the safety interlock indicator is indicative of being on and the wake indicator is indicative of being off, enabling the applying. 